Case Crawler Excavator Cx75sr Cx80 Tier 3 Service Manual

Copyright ©

CRAWLER EXCAVATOR CX75SR/CX80 TIER 3 SERVICE MANUAL TABLE OF CONTENTS DIVISION/SECTION 1

2

3

4

5

6

7

SECTION N°

GENERAL INFORMATION Safety, general information and standard torque data..................................... 1001 General specifications and special torque setting ........................................... 1002 ENGINE Removal and installation of the engine............................................................ 2000 Engine specifications..............................................................................................* Disassembly and assembly of the engine ..............................................................* FUEL SYSTEM Removal and installation of the fuel tank......................................................... 3001 Fuel engine system ................................................................................................*

REFERENCE N° 7-27691EN SC75SRCX80-1002-2EN SM75SR2000-0EN

SM75SR3001-0EN

ELECTRICAL SYSTEM Electrical and engine functions and service support ....................................... 4001 Electrical equipment and electrical circuit diagrams........................................ 4020

SC75SRCX80-4001-0EN SC75SRCX80-4020-0EN

UNDERCARRIAGE Removal and installation of tracks ................................................................... 5001 Rollers ............................................................................................................. 5003 Take-up roller................................................................................................... 5005

SM75SR5001-0EN SM75SR5003-0EN SM75SR5005-0EN

DRIVE TRAIN Removal and installation of the drive motor and final drive transmission................................................................................ 6001 Disassembly and assembly of the drive motor and final drive transmission................................................................................ 6002 Removal and installation of the swing motor and swing reduction gear ................................................................................... 6003 Disassembly and assembly of the swing reduction gear ................................. 6004

SM75SR6001-0EN SM75SR6002-0EN SM75SR6003-0EN See 8019

UNDERCARRIAGE HYDRAULICS

* Consult the Engine Service Manual

CNH

Lep SM75SRTOC-0EN

Copyright © 2008 CNH France S.A. Printed in France March 2008

Copyright © DIVISION/SECTION 8

9

SECTION N°

REFERENCE N°

UPPERSTRUCTURE HYDRAULICS Specifications, troubleshooting, checks and hydraulic pressure settings..........................................................................8001 Removal and installation of the hydraulic reservoir .........................................8002 Removal and installation of the main hydraulic pump......................................8003 Removal and installation of the main hydraulic control valve - CX75SR .........8004 Removal and installation of the main hydraulic control valve - CX80 ..............8004 Removal and installation of the attachment cylinders......................................8005 Removal and installation of the hydraulic swivel ..............................................8006 Removal and installation of the pilot blocs.......................................................8007 Disassembly and assembly of the main hydraulic pump .................................8010 Disassembly and assembly of the main hydraulic control valve - CX75SR .....8011 Disassembly and assembly of the main hydraulic control valve - CX80 ..........8011 Disassembly and assembly of the attachment cylinders .................................8012 Disassembly and assembly of the hand control levers ....................................8013 Disassembly and assembly of the foot control levers ......................................8014 Disassembly and assembly of the solenoid valve block ..................................8015 Disassembly and assembly of the cushion valve.............................................8016 Disassembly and assembly of the hydraulic swivel .........................................8018 Disassembly and assembly of the swing motor ...............................................8019 Hydraulic functions ..........................................................................................8020 Hydraulic component functions........................................................................8030

SC75SRCX80-8001-1EN SM75SR8002-0EN SM75SR8003-0EN SM75SR8004-0EN SM80-8004-0EN SM75SR8005-0EN SM75SR8006-0EN SM75SR8007-0EN SM75SR8010-0EN SM75SR8011-0EN SM80-8011-0EN SM75SR8012-0EN SM75SR8013-0EN SM75SR8014-0EN SM75SR8015-0EN SM75SR8016-0EN SM75SR8018-0EN SM75SR8019-0EN SC75SRCX80-8020-0EN SC75SRCX80-8030-0EN

UPPERSTRUCTURE Air conditioning unit .........................................................................................9007 Large size hydraulic schematics - CX75SR.................................................. Pocket Large size electrical schematics - CX75SR.................................................. Pocket Large size hydraulic schematics - CX80....................................................... Pocket Large size electrical schematics - CX80....................................................... Pocket

SM75SR9007-0EN 87725706A 87732675A KAJ11600-E00 KAJ11060-E00

NOTE: CNH Company reserves the right to make changes in the specification and design of the machine without prior notice and without incurring any obligation to modify units previously sold. The description of the models shown in this manual has been made in accordance with the technical specifications known as of the date of design of this document.

Lep SM75SRTOC-0EN

Issued 03-08

1001

Copyright ©

Section 1001 SAFETY, GENERAL INFORMATION AND TORQUE SPECIFICATIONS

CNH

Lep 7-27691EN

Copyright © 2006 CNH France S.A. Printed in France February 2006

Copyright ©

1001-2

TABLE OF CONTENTS GENERAL INFORMATION .......................................................................................................................................3 SAFETY..................................................................................................................................................................... 4 STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6

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WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message that follows, as there is a risk of serious injury.

Lep 7-27691EN

Issued 02-06

Copyright ©

1001-3

GENERAL INFORMATION Cleanning

Gears

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

Check all gears for wear and damage. Replace gears that have wear or damage.

Inspection Check all parts when the parts are disassembled. Replace all parts that have wear or damage. Small scoring or grooves can be removed with a hone or crocus cloth. Complete a visual inspection for indications of wear, pitting and the replacement of parts necessary to prevent early failures.

Bearings Check bearings for easy action. If bearings have a loose fit or rough action replace the bearing. Wash bearings with a suitable cleaning solvent and permit to air dry. DO NOT DRY BEARINGS WITH COMPRESSED AIR.

Needle bearings Before you press needle bearings in a bore always remove any metal protrusions in the bore or edge of the bore. Before you press bearings into position put petroleum jelly on the inside and outside diameter of the bearings.

Lep 7-27691EN

Oil seals, O-rings and gaskets Always install new oil seals, O-rings and gaskets. Put petroleum jelly on seals and O-rings.

Shafts Check all shafts that have wear or damage. Check the bearing and oil seal surfaces of the shafts for damage.

Service parts Always install genuine Case service parts. When ordering refer to the Parts Catalog for the correct part number of the genuine Case replacement items. Failures due to the use of other than genuine Case replacement parts are not covered by warranty.

Lubrication Only use the oils and lubricants specified in the Operator’s or Service Manuals. Failures due to the use of non-specified oils and lubricants are not covered by warranty.

Issued 02-06

Copyright ©

1001-4

SAFETY

!

This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message. Make sure you fully understand the causes of possible injury or death.

To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual. Put the warning tag shown below on the key for the keyswitch when servicing or repairing the machine. One warning tag is supplied with each machine. Additional tags Part Number 331-4614 are available from your service parts supplier

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WARNING: Before starting engine, study Operator’s Manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operating. It is your responsibility to understand and f o l l o w m a n u f a c tu r e r s i n s tr u c t i o n s o n machine operation, service and to observe pertinent laws and regulations. Operator’s and Service Manuals may be obtained from your Case dealer.

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

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WARNING: When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and use extreme caution.

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WARNING: When doing checks and tests on the equipment hydraulics, follow the procedures as they are written. DO NOT change the procedure.

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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.

.

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WARNING: Read the operator’s manual to familiarize yourself with the correct control functions.

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WARNING: Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury.

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WARNING: This is a one man machine, no riders allowed.

Lep 7-27691EN

Issued 02-06

Copyright ©

1001-5

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WARNING: When servicing or repairing the machine, keep the shop floor and operator’s compartment and steps free of oil, water, grease, tools, etc. Use an oil absorbing material and/or shop cloths as required. Use safe practices at all times.

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WARNING: Some components of this machine are very heavy. Use suitable lifting equipment or additional help as instructed in this Service Manual.

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

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

WARNING: Use insulated gloves or mittens when working with hot parts.

WARNING: Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or service.

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

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WARNING: When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer.

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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).

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WARNING: Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor. Always block machine in place with suitable safety stands.

Lep 7-27691EN

Issued 02-06

Copyright ©

1001-6

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS Tightening of cap screws, nuts Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the order of tightening.

JS00481A

Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or suitable cleaning solvent and dried. Apply 2-3 drops of Loctite to the thread portion of the cap screw and then tighten.

Torque table Tighten cap screws and nuts according to the table below if there are no other special instructions.

Cap Screw Name Size (Size) Spanner Cap Screw Tightening torque

Spanner Socket Head Cap Screw

Lep 7-27691EN

Tightening torque

M6 [mm]

M8

M10

M12

M14

M16

M18

M20

10

13

17

19

22

24

27

30

[in.]

0.39

0.51

0.67

0.75

0.87

0.95

1.06

1.18

[Nm]

6.9

19.6

39.2

58.8

98.1

156.9

196.1

294.2

[lb-ft]

5.1

14.5

28.9

43.4

72.3

115.7

144.6

217

[mm]

5

6

8

10

12

14

14

17

[in.]

0.20

0.24

0.32

0.39

0.47

0.55

0.55

0.67

[Nm]

8.8

21.6

42.1

78.5

117.7

176.5

245.2

343.2

[lb-ft]

6.5

15.9

31.1

57.9

86.9

130.2

181

253.2

Issued 02-06

1002

Copyright ©

Section 1002 SPECIFICATIONS AND SPECIAL TORQUE SETTINGS

CNH

Lep SC75SRCX80-1002-0EN

Copyright @ 2008 CNH France SA Printed in France Mars 2008

Copyright © 1002-2

TABLE OF CONTENTS

!

WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message which follows. Your safety depends on it.

TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE..................................................................................................... 5 Machine ....................................................................................................................................................................... 5 Engine .......................................................................................................................................................................... 5 Serial numbers of the components .............................................................................................................................. 5 FLUIDS AND LUBRICANTS ............................................................................................................................................ 6 Hydraulic fluid .............................................................................................................................................................. 6 Transmission component oil ........................................................................................................................................ 6 Grease ......................................................................................................................................................................... 6 Engine Oil .................................................................................................................................................................... 7 Engine fuel, maintenance of fuel filters and fuel storage ............................................................................................. 8 Anti-freeze/Anti-corrosion........................................................................................................................................... 10 Environment ............................................................................................................................................................... 10 Plastic and resin parts................................................................................................................................................ 10 SPECIFICATIONS ......................................................................................................................................................... 11 Main data ................................................................................................................................................................... 11 Performance .............................................................................................................................................................. 11 Main body dimensions ............................................................................................................................................... 11 Engine ........................................................................................................................................................................ 11 Cooling system .......................................................................................................................................................... 12 Capacity of coolant and lubricants ............................................................................................................................. 12 Air conditioning .......................................................................................................................................................... 12 Hydraulic oil filter........................................................................................................................................................ 12 Fuel filter .................................................................................................................................................................... 12 Operating devices ...................................................................................................................................................... 12 Hydraulic system........................................................................................................................................................ 13 Hydraulic Cylinders .................................................................................................................................................... 15 Rotating Joint ............................................................................................................................................................. 16 Swing unit .................................................................................................................................................................. 21 Travel lower body....................................................................................................................................................... 21 Work Unit ................................................................................................................................................................... 22 COMPONENT WEIGHT................................................................................................................................................. 24 Major component weight (CX75SR)........................................................................................................................... 24 Major component weight (CX80)................................................................................................................................ 25 Other component weight ............................................................................................................................................ 26 DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY .................................................................................. 27 Sprocket ..................................................................................................................................................................... 27 Idler wheel.................................................................................................................................................................. 28 Upper roller ................................................................................................................................................................ 29 Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-3 Lower roller .................................................................................................................................................................30 Track...........................................................................................................................................................................31 DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES (MONO BOOM) ...................................................32 1. Boom foot/Frame ....................................................................................................................................................32 2. Boom cylinder foot/Frame.......................................................................................................................................33 3. Boom cylinder head/Boom......................................................................................................................................33 4. Dipper cylinder foot/Boom ......................................................................................................................................34 5. Boom/Dipper...........................................................................................................................................................34 6. Dipper cylinder head/Dipper ...................................................................................................................................34 7. Bucket cylinder foot/Dipper.....................................................................................................................................35 8. Connecting rod/Dipper............................................................................................................................................35 9. Compensator/Bucket ..............................................................................................................................................35 10. Connecting rod/Compensator/Bucket cylinder head ............................................................................................36 11. Dipper/Bucket .......................................................................................................................................................36 DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES (CX75SR OFFSET BOOM) .................................37 1. Base Boom/Offset boom.........................................................................................................................................37 2.Base Boom/Offset cylinder/Rod...............................................................................................................................38 3. Offset Boom/ Offset cylinder...................................................................................................................................38 4. Offset Dipper/Rod ...................................................................................................................................................39 5. Offset arm/Offset Boom ..........................................................................................................................................39 6. Offset Dipper/ Dipper cylinder.................................................................................................................................39 7. Offset dipper/Dipper................................................................................................................................................40 8. Dipper/Dipper cylinder ............................................................................................................................................40 9. Dipper/Bucket cylinder............................................................................................................................................40 DIMENSIONS AND WEAR LIMITS OF BLADE AND BLADE CYLINDER .....................................................................41 10. Blade/Blade cylinder .............................................................................................................................................41 11. Lower frame/Blade cylinder ..................................................................................................................................41 12. Lower frame/Blade................................................................................................................................................42 LIST OF SHIMS ..............................................................................................................................................................43 For Adjusting Attachment Gaps..................................................................................................................................43 For Adjusting Attachment Gaps (for Boom Foot)........................................................................................................47 SPECIAL TORQUE SETTINGS CX75SR.......................................................................................................................49 SPECIAL TORQUE SETTINGS CX80............................................................................................................................52 MACHINE OVERALL DIMENSIONS ..............................................................................................................................55


Issued 03-08

Copyright © 1002-4


Issued 03-08

Copyright © 1002-5

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

Machine

1 2

3

CT04A171A

(1) Type ....................................................................................................................................................................... (2) Serial number......................................................................................................................................................... (3) Year of manufacture ...............................................................................................................................................

Engine Make and type............................................................................................................................................................. Serial number ..............................................................................................................................................................

Serial numbers of the components Hydraulic pump ........................................................................................................................................................... Swing reduction gear................................................................................................................................................... Travel reduction gears ................................................................................................................................................. Control valve................................................................................................................................................................


Issued 03-08

Copyright © 1002-6

FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application.

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WARNING: The conditions of use for individual fluids and lubricants must be respected.

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

Transmission component oil Extreme pressure oil used for enclosed transmission components. CASE/AKCELA: GEAR 135H EP (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)

Grease CASE/AKCELA: MOLY GREASE 251H EP-M (251H EP-M. NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap and molybdenum disulphide. CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (251H EP. NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap and calcium. CASE/AKCELA: PREMIUM GREASE EP2 (NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap.

Hydraulic breakers CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2).


Issued 03-08

Copyright © 1002-7

Engine Oil THE CASE/AKCELA No. 1 engine oil is recommended for your engine. This oil ensures proper lubrication of your engine for all operating conditions. If the CASE/AKCELA Multigrade "No. 1 ENGINE OIL" cannot be obtained, use the oil corresponding to one of the following categories: ACEA E7. API CI-4.

CP02N001

Oil viscosity / Oil range

1 2 2 3 3

CT02M001

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


Issued 03-08

Copyright © 1002-8

Engine fuel, maintenance of fuel filters and fuel storage In order to meet the emission control regulation of 3rd-stage, the engine components have been made precisely and they are to be used under high-pressure conditions. Therefore, the specified fuel must be used for the engine. As a matter of course, not only the guarantee will not be given for the use of a fuel other than the specified but also it may invite a serious breakdown. In addition, since suitable specifications for the fuel filter elements have been established for this engine, use of the genuine filter is essential. The following describes the specifications and the requirements of the fuel to be applied, and maintenance of the fuel and the fuel elements.

Fuel to be applied Selection of fuel Following conditions must be met for the diesel engines, that is the one; 1 In which no dust even fine one is mixed, 2 With proper viscosity, 3 With high cetane rating, 4 With good flow properties in lower temperature, 5 With not much sulfur content, and 6 With less content of carbon residue Applicable standards for diesel fuel Applicable Standard

Recommendation

JIS (Japanese Industrial Standard)

NO.2

DIN (Deutsche Industrie Normen)

DIN 51601

SAE (Society of Automotive Engineers) Based on SAE-J-313C

NO. 2-D

BS (British Standard) Based on BS/2869-197

Class A-1

EN590 If a standard applied to the fuel for the diesel engine is stipulated in your country, check the standard for details. Requirements for diesel fuel Although conditions required for the diesel fuel are illustrated above, there are other requirements exerting a big influence on its service durability and service life. Be sure to observe the following requirements for selecting fuel. Sulfur content............................................................................... 2500 ppm or less HFRR*.......................................................................................... 460 mm or less Water content............................................................................... 0.05 wt% or less * HFRR (High-Frequency Reciprocating Rig.): An index showing lubricating properties of the fuel. Sulfur content reacts to moisture to change into sulfuric acid after combustion. Use of a fuel containing much sulfur content allows it to accelerate internal corrosion and wear. In addition, much sulfur content quickens deterioration of engine oil allowing its cleaning dispersive property to be worse which results in acceleration of wear of sliding portions. HFRR is an index that indicates lubricating property of a fuel. Large value of the index means poor lubrication so that seizure of the machine components may result if such a fuel is used. Since a fuel with high HFRR value also has lower viscosity, it can easily be leaked out. Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-9 If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property resulting in acceleration of wear. Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the fuel filter. IMPORTANT : In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of condensation. This may also cause wear and seizure of the machine components. If atmospheric temperature goes below the freezing point, moisture content in the fuel forms fine particle of ice allowing the fuel line to be clogged. IMPORTANT : Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it meets the criteria described above. IMPORTANT : If a fuel which does not meet the specifications and the requirements for the diesel engine, function and performance of the engine will not be delivered. In addition, never use such a fuel because a breakdown of the engine or an accident may be invited. Guarantee will not be given to a breakdown caused by the use of a improper fuel. Some fuels are used with engine oil or additives mixed together with diesel engine fuel. In this case, do not use these fuels because damage to the engine may result as the fuel has been contaminated. It is natural that the emission control regulation of 3rd-stage will not be cleared in case where a fuel that does not meet the specifications and the requirements is used. Use the specified fuel for compliance of the exhaust gas control. IMPORTANT : It you use diesel fuel which contains much sulfur content more than 2500 ppm, be sure to follow the items below for the engine oil selection and maintenance of engine parts. Guarantee will not be given to breakdowns caused by not to follow these items. 1 Selection of engine oil Use API grade CF-4 or JASO grade DH-1. 2 Exchange the engine oil and engine oil filter element by the periodical interval reported on the Operator’s Manual. 3 Inspect and exchange the EGR (*)parts and fuel injector parts of engine every 3000 hour of use. * EGR: Exhaust Gas Recircultion

Maintenance of fuel filters Be sure to use the genuine fuel filters. The fuel injection system is precisely constructed and the genuine filter employs finer mesh than conventional filters to improve protection of machine equipment. If a filter with coarse mesh is used, foreign object passing through the filter enters into the engine so that machine equipment can wear out in a short period of time. IMPORTANT : If a fuel filter other than the genuine filter is used, guaranty will not be applied to a fault caused by the use of a wrong filter. Two kinds of fuel filter, the pre-filter and the main filter, are mounted on the machine. Be sure to use the genuine fuel filters and replace them at the periodic intervals reported on the operator’s Manual. IMPORTANT : Since the pre-filter also has a function of water separation, discharge water and sediment when the float reaches lower part of the filter elements. CHECK EVERY DAY before to start the engine. Time to replace filters may be advanced according to properties of the fuel being supplied. • Therefore, take measures to prevent dust or water from being entered in the fuel tank when supplying fuel. • When supplying fuel directly from a fuel drum can, leave the drum as it stands for a long period of time to supply clean fuel standing above a precipitate. • If it is hard to leave the drum for a long period of time, install a fuel strainer and a water separator before the fuel tank of the machine to supply clean fuel. Water drain cock is provided on the bottom side of the fuel tank. • Drain water before starting the engine every morning. • In addition, remove the cover under the tank once a year to clean up inside of the tank.


Issued 03-08

Copyright © 1002-10

Fuel storage Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel. The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing. CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710) For areas where the temperature goes down to -38°C (-36.4°F), mix 50/50 with water. IMPORTANT : Do not mix products of a different origin or brand. The same product must be used when topping up the system.

Environment Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles. Contact your local ecological recycling centre or your CASE Dealer to obtain information on the correct method of disposing of these lubricants.

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


Issued 03-08


SPECIFICATIONS Main data Model name ...............................................CX75SR, CX80 (Mono Boom), CX75SR (Offset Boom) Hydraulic Excavator Operating weight: Mono Boom ...............................................................................................................................7950 kg (17526.73 lbs) Mono Boom (CX80) ........................................................................................................................ 8470 kg (18673 lbs) Offset Boom (CX75SR) .............................................................................................................. 8290 Kg (18276.3 lbs) Engine output ......................................................................................................................................... 40 kW / 1800 rpm

Performance Swing speed....................................................................................................................................................... 9.5 Tr/min. Travel speed: Low Speed.................................................................................................................................... 3.3 km/h (2.05 mph) High Speed .................................................................................................................................... 5.1 km/h (3.16 mph) Maximum drawbar pull .................................................................................................................... 59.5 kN (13376.13 lbf) Maximum drawbar pull (CX80)....................................................................................................................... 59.2 kN ( lbf) Grade ability ........................................................................................................................................................70% (35°) Ground pressure: Mono Boom .................................................................................................. 36 kPa (450 mm (17.72 in) grouser shoe) Offset Boom.................................................................................................. 37 kPa (450 mm (17.72 in) grouser shoe)

Main body dimensions Main body length............................................................................................................................... 3280 mm (129.13 in) Main body length (CX80) .................................................................................................................. 3510 mm (138.18 in) Main body width .................................................................................................................................. 2320 mm (91.34 in) Upper swing body width ...................................................................................................................... 2225 mm (87.60 in) Cab width ............................................................................................................................................ 1065 mm (41.93 in) Main body height............................................................................................................................... 2700 mm (106.30 in) Main body height (CX80) 1.71 m (Arm)................................................................................................................................. 2700 mm (106.29 in) 2.12 m (Arm)................................................................................................................................. 2950 mm (116.14 in) Swing radius (rear end)....................................................................................................................... 1235 mm (48.62 in) Swing radius (rear end), (CX80) ......................................................................................................... 1655 mm (65.15 in) Swing body rear end distance............................................................................................................. 1235 mm (48.62 in) Swing body rear section bottom height ................................................................................................. 745 mm (29.33 in) Distance between tumblers...................................................................................................................... 2210 mm (87 in) Overall track length ................................................................................................................................ 2845 mm (112 in) Overall track width............................................................................................................................... 2320 mm (91.33 in) Distance between tracks ..................................................................................................................... 1870 mm (73.62 in) Width of track shoe .............................................................................. 450 mm (17.72 in), (Optional: 600 mm (23.62 in)) Minimum ground clearance (To bottom of lower frame) ........................................................................ 360 mm (14.17 in)

Engine Name..................................................................................................................................................... ISUZU, AU-4LE2X Type: ........................................................................ water-cooled, 4-cycle diesel, 4-cylinder in-line, direct injection type ............................................................................................. (electronic control), turbocharger with air cooled intercooler. No. of cylinders - bore x stroke................................................................................. 4 - Ø85 mm x 96 mm (3.35 x 3.78 in) Displacement .................................................................................................................................. 2179 cc (132.98 cu-in) Compression ratio ........................................................................................................................................................18.3 Rated output ........................................................................................................................................ 40 kW / 2000 min-1 Maximum torque ................................................................................................... 200 N.m (147.51 lb-ft) / 2000rpm min-1 Fuel consumption ratio.............................................................................................................................. 240g/KW.h max Engine dimensions (LxWxH)........................................................................ 757.1x650.7x753.7 mm (29.8 x25.6x29.7 in) Oil pan............................................................................................................................... All direction 0.61 rad, inclinable Oil pan capacity........................................................ Maximum: 10.4 L (2.7 gal) Minimum: 7 L (2 gal) (excluding oil filter) Direction of rotation ...................................................................................................................... Right (as seen from fan) Starter, reduction type.....................................................................................................................................24 V, 3.2 kW Alternator, AC type ............................................................................................................................................. 24 V, 50 A Battery..................................................................................................................................................2 x 12V, 64 Ah/5 Hr


Issued 03-08


Cooling system Fan type............................................................................................ Ø 650 mm (25.59 in), suction type - 7 blades, intake Radiator Capacity .................................................................................................................................................... 5.1L (1.3 gal) Fin type .................................................................................................................................................................. wavy Fin pitch ................................................................................................................................................ 2 mm (0.079 in) Oil cooler Capacity ................................................................................................................................................... 4.4 L (1.2 gal) Fin type .................................................................................................................................................................. wavy Fin pitch ........................................................................................................................................... 1.75 mm (0.069 in) Inter-cooler Capacity ................................................................................................................................................... 4.1 L (1.1 gal) Fin type .................................................................................................................................................................. wavy Fin pitch ........................................................................................................................................... 1.75 mm (0.069 in)

Capacity of coolant and lubricants Coolant ..................................................................................................................................................... 10.2 L (2.70 gal) Fuel ......................................................................................................................................................... 100 L (26.42 gal) Lubricant for engine....................................................................................................................................... 9 L (2.38 gal) Lubricant for travel reduction gear (one side) ............................................................................................. 1.1 L (0.29 gal) Hydraulic oil............................................................................................................................................ 97.3 L (25.70 gal) Capacity of hydraulic oil tank..................................................................................................................... 50 L (13.21 gal)

Air conditioning R134 gas load ..............................................................................................................................................1Kg (2.20 Ibs)

Hydraulic oil filter Suction filter (inside tank) ....................................................................................................................................150 mesh Return filter (inside tank) ............................................................................................................................................ 6 µm Pilot line filter (inside housing).................................................................................................................................... 8 µm

Fuel filter Main filter.................................................................................................................................................................... 4 µm Pre-filter.................................................................................................................................................................... 10 µm

Operating devices Operator's seat Location: left side Structure: Adjustable forward and back and up and down, reclining mechanism, with seat suspension. Cab Sealed steel type, all reinforced glass. Levers and pedals For travel use: Lever and pedal type (hydraulic pilot type) (x2) For operating machine use: Lever type (hydraulic pilot type) (x2) For blade use: Lever type (hydraulic pilot type) (x1) For offset-boom operating use (CX75SR)............................................................. Pedal type (hydraulic pilot type) (x1) Instruments and switches Work mode select switch: 2 modes (N/Standard operating mode, E/Economy operating mode) Travel mode select switch: Low-speed/high-speed switch type One-touch idle: Knob switch type Engine emergency stop: Switch type Monitor device Machine status display (full-dot liquid crystal) Work mode selection status: N/E Instruments (full-dot liquid crystal, except for hour meter) Fuel gauge: Analog Engine coolant temperature gauge: Analog Hour meter: digital type Machine Status and Warning Alarms *Items have a warning alarm Over heat* Battery charge* Check engine* Refill fuel* Lep SC75SRCX80-1002-0EN

Engine oil pressure*

Engine preheat Issued 03-08

Copyright © 1002-13 Lighting Working light

Cab top:

24V, 55W (x1)

Boom up:

24V, 70W (x1)

Interior light Horn

24V, 6W (x1) Electric horn

x2

Other Wiper with intermittent function, window washer, air conditioner, rear view mirrors, clock

Hydraulic system Hydraulic pump drive system, direct engine link (no transmission) Main pump Manufacturer ...................................................................................................................................... Bosch Rexroth Pump type ........................................................................................double variable displacement piston pump x 1 Gear pump ........................................................................................................................................................... x 2 Gear pump (for blade use) ........................................................................................................................24.2 L/min Displacement volume ..................................................................................................34.0 cm3 (2.07 cu in) x 2 /rev Operating pressure Rated .................................................................................................... 29.4 MPa (4264.11 psi) Input revolution speed Rated................................................................................................. 2000 min-1 (2000 rpm) Maximum input revolution speed ........................................................................................... 2250 min-1 (2250 rpm) Maximum discharge flow ........................................................68 x 2 L/min at 2000 min-1 (18 x 2 gpm at 2000 rpm) Pilot pump Pump type ................................................................................................................Fixed displacement gear pump Displacement volume ......................................................................................................... 10.7 cm3 (0.65 cu in)/rev Operating pressure........................................................................................................................ 4.2 MPa (610 psi) Maximum flow.................................................................................................... 21.4 L/min (5.6 gpm) at 2000 min-1 Gear pump (for blade) Pump type ................................................................................................................Fixed displacement gear pump Displacement volume .......................................................................................................................... 12.1 cm3 / rev Operating pressure.................................................................................................................... 22.6 MPa (3280 psi) Maximum flow.................................................................................................... 24.2 L/min (6.4 gpm) at 2000 min-1 Control method Full hosepower angle control in concurrence. Horsepower control by blade pump operation pressure. Set pressure of main relief valve Boom/Arm/ Bucket/Travel .................................................................................................... 29.4 MPa (4264.11 psi) Swing.................................................................................................................................... 22.6 MPa (3277.85 psi) Blade .................................................................................................................................... 22.6 MPa (3277.85 psi) Set pressure of overload relief valve Boom/Arm/ Bucket............................................................................................................... 31.9 MPa (4626.70 psi) Blade .................................................................................................................................... 25.5 MPa (3698.46 psi) Control Valve Model; Double spool x 1 Quintuple spool x 2 Operation method: hydraulic pilot method: travel, swing, blade and operating machine Maximum flow Mono Boom with blade ................................................................................... 75.8 L / min (20 gpm) (at 2230 min-1) Offset Boom with blade (CX75SR) .............................................................. 75.2 L / min (19.8 gpm) (at 2320 min-1) Overload set pressure Other: Mono Boom with blade .......................................................................... 31.9 ± 0.3 MPa (4630 ± 44 psi) at 20 L/min Offset Boom with blade (CX75SR) ........................................................ 31.9 ± 0.3 MPa (4630 ± 44 psi) at 20 L/min Boom (CX80): Swing right ........................................................................................ 33.3 ± 0.3 MPa (4830 ± 44 psi) at 20 L/min Swing left .......................................................................................... 31.9 ± 0.3 MPa (4630 ± 44 psi) at 20 L/min Boom up/down (CX75SR) Mono Boom with blade ..................................................................... 25.5 ± 0.3 MPa (3700 ± 44 psi) at 20 L/min Offset Boom with blade..................................................................... 25.5 ± 0.3 MPa (3700 ± 44 psi) at 20 L/min Offset right (CX75SR) Offset Boom with blade..................................................................... 31.9 ± 0.3 MPa (4630 ± 44 psi) at 20 L/min Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-14 Offset left (CX75SR) Offset Boom with blade ..................................................................... 33.3 ± 0.3 MPa (4830 ± 44 psi) at 20 L/min Main relief set pressure ................................................................................. 29.4 ± 0.3 MPa (4260 ± 0.4 psi) at 44 L/min Functions Travel priority Boom up / arm 2 pumps internal flow Boom load holding circuit Arm-in forced regenerative circuit Swing priority 2 pumps flow is joined at reserve section


Issued 03-08


Hydraulic Cylinders Mono boom spec. with dozer blade

Offset boom spec. with dozer blade

Boom cylinder Cylinder bore ................................................................................. Ø110 mm (Ø4.33 in) Rod diametre ................................................................................... Ø70 mm (Ø2.75 in) Maximum retracted length ...............................................................1408 mm (55.43 in) Stroke ................................................................................................911 mm (35.87 in) Arm (dipper) cylinder Cylinder bore ................................................................................... Ø95 mm (Ø3.74 in) ............Ø95 mm (Ø3.74 in) Rod diametre ................................................................................... Ø60 mm (Ø2.36 in) ............Ø60 mm (Ø2.36 in) Maximum retracted length ....................................................................1270 mm (50 in) ............... 240 mm (9.45 in) Stroke ................................................................................................797 mm (31.38 in) ............. 685 mm (26.97 in) Bucket cylinder Cylinder bore ................................................................................... Ø85 mm (Ø3.35 in) Rod diametre ................................................................................... Ø55 mm (Ø2.16 in) Maximum retracted length ...............................................................1035 mm (40.75 in) Stroke ................................................................................................665 mm (26.18 in) Blade cylinder Cylinder bore ................................................................................. Ø100 mm (Ø3.94 in) Rod diametre ................................................................................... Ø60 mm (Ø2.36 in) Maximum retracted length .................................................................530 mm (20.87 in) Stroke ..................................................................................................180 mm (7.09 in) Offset cylinder (CX75SR) Cylinder bore ................................................................................... Ø95 mm (Ø3.74 in) Rod diametre ................................................................................... Ø55 mm (Ø2.16 in) Maximum retracted length ..............................................................710 mm (Ø27.95 in) Stroke .............................................................................................315 mm (Ø12.40 in) Boom swing cylinder (CX80) Cylinder bore ................................................................................... Ø95 mm (Ø3.74 in) Rod diametre ................................................................................... Ø55 mm (Ø2.16 in) Maximum retracted length ..................................1085 ± 30 mm (Ø42.71 in ± 1.18 mm) Stroke ................................................................640 ± 2.0 mm (Ø25.19 in ± 0.078 mm)


Issued 03-08


Rotating Joint Operating pressure High pressure passage (ABCDEF)............................................................................................ 29.4 MPa (4260 psi) Drain port (T) .............................................................................................................................. 0.5 MPa (72.52 psi) Pilot port (P)................................................................................................................................... 3.9 MPa (566 psi) Flow High pressure passage (ABCDEF)............................................................................................... 68 L/min (18 gpm) Drain port (T) .................................................................................................................................. 15 L/min (4 gpm) Pilot port (P).................................................................................................................................... 23 L/min (6 gpm) Port A; forward right ................................................................................................................................................G1/2 Port B; forward left ..................................................................................................................................................G1/2 Port C; backward right.............................................................................................................................................G1/2 Port D; backward left ...............................................................................................................................................G1/2 Port E; blade up ..................................................................................................................................................... G3/8 Port F; blade down ..................................................................................................................................................G3/8 Port T; drain port .....................................................................................................................................................G3/8 Port P; pilot port ......................................................................................................................................................G1/4 Number of revolutions....................................................................................................................15 min-1 (15 rpm) Torque: No load ...................................................................................................................................... 160 Nm (1420 lbf.in) When pressurizing 2 ports......................................................................................................... 190 Nm (1480 lbf.in) Solenoid Valve (4 stack) Manufacturer ................................................................................................................................ Yuken kogyo co., LTD Maximum flow ............................................................................P -> B: 20 L/min (5.3 gpm) Other: 5 L/min (1.32 gpm) Rated pressure ............................................................................................................................. 4.5 MPa (652.67 psi) Port size P, T, B port...........................................................................................................................................................G3/8 C1, C2, C3 port...................................................................................................................................................G1/4 Solenoid specifications Operating voltage ................................................................................................................................DC 20 to 32 V Power consumption .................................................................................................................................. 17 W max.


Issued 03-08

Copyright © 1002-17 Hand control valve Manufacturer................................................................................................................................................... Kawasaki Operating pressure .......................................................................................................................... 3.92 MPa (569 psi) Secondary pressure, primary short type .......................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi) Operating angle Ports 1, 3 .............................................................................................................................................................. 19° Ports 2, 4 .............................................................................................................................................................. 25° Operating torque Ports 1 ................................................................................................................... 0.58 - 2.03 Nm (0.42 - 1.49 (lb-ft) Ports 3 ................................................................................................................... 0.47 - 1.92 Nm (0.34 - 1.41 (lb-ft) Ports 2, 4 ............................................................................................................... 0.71 - 2.30 Nm (0.52 - 1.69 (lb-ft) Port 1, 3

Port 2, 4

4.0 Secondary pressure

Secondary pressure (MPa)


4.0

3.0

2.0

1.0

0

0

3.0

2.0

1.0

Secondary pressure

0

2 4 6 Push rod stroke (mm)

7

5 10 15 Operating angle (deg.)

19

0

2

4 6 Push rod stroke (mm)

8

5

10 15 20 Operating angle (deg.)

9.4 25

RST-03-01-001B

Foot control valve (for travel) Manufacturer....................................................................................................................................... Nishina industrial Operating pressure .......................................................................................................................... 3.92 MPa (569 psi) Secondary pressure, primary short type .......................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi) Operating angle ..................................................................................................................................................... 12.4° Operating torque Valve....................................................................................................................... 2.62 - 8.58 Nm (1.93 - 6.33 lb-ft) Damper................................................................................................................... 6.87 Nm at 0.018 m/s (60.8 lb-ft)


3.9

3.0

2.0

1.0

Secondary pressure

0

2 4 5.5 Push rod stroke (mm) 0

5 10 12.4 Operating angle (deg.) RST-03-01-001D


Issued 03-08


Operating torque (Nm) (lbf-ft)


Foot control valve (for Dozer Blade) Manufacturer ....................................................................................................................................... Nishina industrial Operating pressure .......................................................................................................................... 3.92 MPa (569 psi) Secondary pressure, primary short type........................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi) Operating angle......................................................................................................................................................... 10° Operating torque ............................................................................................................................See the figure below

Secondary pressure

Operating angle (deg.)

Push rod stroke (mm) (in)


Issued 03-08



Operating torque (Nm) (lbf-ft)

Foot control valve (for Offset Boom) (CX75SR) Manufacturer....................................................................................................................................... Nishina industrial Operating pressure .......................................................................................................................... 3.92 MPa (569 psi) Secondary pressure, primary short type .......................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi) Operating angle ..................................................................................................................................................... 12.4° Operating torque............................................................................................................................ See the figure below

Secondary pressure

Operating angle (deg.)

Push rod stroke (mm) (in)


Issued 03-08

Copyright © 1002-20 Foot control valve (for Boom Swing) (CX80) Manufacturer ....................................................................................................................................... Nishina industrial Operating pressure .......................................................................................................................... 3.92 MPa (570 psi) Secondary pressure, primary short type................................................. 0.59 ± 0.1 to 3.14 ± 0.3MPa (85.6 to 455 psi) Operating angle.............................................................................................................................................10.0 ± 0.3° Operating torque .......................................................................................................2.80 to 5.70 Nm (2.06 to 4.20 psi)


Issued 03-08


Swing unit Swing circle ........................................................................................................... Swing bearing type (with internal gear) Swing hydraulic motor ..................................................................................................... Fixed displacement piston motor Reduction gear....................................................................................................... Planetary gear 2-stage reduction gear Swing parking brake................................................................................ Mechanical lock (operational lever linkage type) Displacement .............................................................................................................................................44.1 cm3 /rev Operating pressure ........................................................................................................................ 22.6 MPa (3280 psi) Operating flow................................................................................................................................... 68 L/min (18 gpm) Mechanical brake torque ................................................................................................... 174.1 Nm (1540.7 lb-ft) min. Brake off pressure .................................................................................................................4.9 MPa (710.68 psi) max Relief valve set pressure ....................................................... 22.6 ± 0.3 MPa at 57.5 L/min (3280 ± 44 psi at 15 gpm) Reduction gear....................................................................................................... Planetary gear 2-stage reduction gear Reduction ratio.....................................................................................................................................................20.615

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


Issued 03-08


Work Unit Model..................................................................................................................................................Backhoe attachment Components / dimensions / working dimensions

CX75SR Model

MONO BOOM

Boom length Arm type

OFFSET BOOM

3870 mm (152.36 in) Standard 1.710 mm (67.32 in)

Long 2.120 mm (83.46 in)

Standard 1.750 mm (68.90 in)

1710 mm (67.32 in)

2120 mm (83.46 in)

1740 mm (68.50 in)

Bucket capacity

Heaped 0.28 m3 (Leveled 0.20 m3)



Bucket width

730 mm (28.74 in)

600 mm (23.62 in)

730 mm (28.74 in)

Bucket width with side cutter

804 mm (31.65 in)

673 mm (26.50 in)

804 mm (31.65 in)

Bucket weight with side cutter

204 kg (449.74 lb)

178 kg (392.42 lb)

204 kg (449.74 lb)

1450 mm (57.08 in)

1050 mm (41.34 in)

1450 mm (57.08 in)

Arm (dipper) length

Bucket radius Bucket wrist action

177°

Maximum digging radius

6520 mm (256.69 in)

6900 mm (271.65 in)

6080 mm (239.40 in)

Maximum digging radius at ground line

6390 mm (251.57 in)

6770 mm (266.53 in)

6360 mm (250.39 in)

Maximum digging depth

4140 mm (162.99 in)

4540 mm (178.74 in)

4190 mm (164.96 in)

Maximum vertical straight wall digging radius

3640 mm (143.31 in)

4100 mm (161.42 in)

4580 mm (180.31 in)

Maximum digging height

7330 mm (288.58 in)

7620 mm (300 in)

7195 mm (283.27 in)

Maximum dump height

5250 mm (206.69 in)

5540 mm (218.10 in)

5150 mm (202.75 in)

Minimum swing radius at front

1785 mm (70.27 in)

2085 mm (82.08 in)

2230 mm (87.79 in)

Height for minimum swing radius at front

5620 mm (221.26 in)

5650 mm (222.44 in)

5700 mm (224.41 in)


Issued 03-08


CX80 Model

MONO BOOM

Boom length Arm type

3500 mm (137.79 in) Standard 1.710 mm (67.32 in)

Long 2.120 mm (83.46 in)

1710 mm (67.32 in)

2120 mm (83.46 in)

Bucket capacity



Bucket width

730 mm (28.74 in)

600 mm (23.62 in)

Bucket width with side cutter

804 mm (31.65 in)

673 mm (26.50 in)

Bucket weight with side cutter

204 kg (449.74 lb)

178 kg (392.42 lb)

1050 mm (41.34 in)

1050 mm (41.34 in)

Arm (dipper) length

Bucket radius Bucket wrist angle

177°

Maximum digging radius

7030 mm ( 276.77 in)

7400 mm (291.33 in)

Maximum digging radius at ground line

6390 mm (275.19 in)

7270 mm (286.21 in)

Maximum digging depth

4180 mm (164.56 in)

4590 mm (180.70 in)

Maximum vertical straight wall digging radius

3080 mm (121.25 in)

3550 mm (139.76 in)

Maximum digging height

6390 mm (251.57 in)

6600 mm (259.84 in)

Maximum dump height

4390 mm (172.83 in)

4600 mm (181.10 in)

Minimum swing radius at front

2750 mm (108.26 in)

2910 mm (114.56 in)

Height for minimum swing radius at front

5060 mm (199.21 in)

5080 mm (199.99 in)


Issued 03-08


COMPONENT WEIGHT Major component weight (CX75SR) (MONO BOOM)

(OFFSET BOOM)

AQ29001-001_EU

Weight (kg) information is approximate Symbol

Component Name

MONO BOOM SPEC.

OFFSET BOOM SPEC.

A

Operating weight

7952 (17531 lbs)

8292 (18280 lbs)

B

Upper mechanism (including counterweight and turntable bearing

3892 (8580 lbs)

3892 (8580 lbs)

C

Counterweight

1357 (2991 lbs)

1357 (2991 lbs)

D

Lower mechanism (with standard grouser shoe)

2801 (6175l bs)

2801 (6175 lbs)

E

Main Unit Weight

6693 (14755 lbs)

6691 (14751 lbs)

F

Attachments

1176 (2592 lbs)

1518 (3346 lbs)

G

Boom (including cylinders)

703 (1549 lbs)

1043 (2299 lbs)

H

Arm (dipper) (including cylinders and linkage)

263 (579 lbs)

266 (586 lbs)

I

Blade

332 (732 lbs)

332 (732 lbs)


Issued 03-08


Major component weight (CX80)

B A

C

D

E

F

H

I

G

AS09001-001

Weight (kg) information is approximate Symbol

Component Name

A

Operating weight

8470 (18673 lbs)

B

Upper mechanism (including counterweight and turntable bearing

4527 (9980 lbs)

C

Counterweight

1237 (2727 lbs)

D

Lower mechanism (with standard grouser shoe)

2801 (7175 lbs)

E

Main Unit Weight

7328 (16155 lbs)

F

Attachments

1063 (2343 lbs)

G

Boom (including cylinders)

595 (1311 lbs)

H

Arm (dipper) (including cylinders and linkage)

262 (577 lbs)

I

Blade

332 (732 lbs)


Issued 03-08


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


Issued 03-08


DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY Sprocket Dimensions a

P

Ød

Øb Øc

CS01B512

Mark

Dimension (mm) Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

a Øb Øc Ød P

35 30 480.81 474.91 533.61 527.61 522.47 --154 ---

Gauge 185 153 - 155 48.89

12

3.9

.7

°

7° 40.

3.9

25

R

R3

.8 53

R2

0.8

to 6

R

21.6

15.1

70

82.8

90° .7 28

17.1°

17.1°

AQ19002-031A


Issued 03-08


Idler wheel Dimensions Mark

Dimension (mm)

Standard Øa Limit Standard b Limit Standard c Limit Standard Ø d (shaft) Limit Standard Ø d (bushing) Limit Standard e Limit Standard f Limit

c b

Øa

e

400 369 28 25 44 40 42 41 42 42.8 42 41.6 20 19.5

f

Ød

AQ19002-001A

Gauge

110 94 - 98 39 - 44 38.4 10°

28

R 6-

40°

3°

10

5 2-

5

R3 AQ19002-032A


Issued 03-08


Upper roller Dimensions Mark Øa

80 70 30 ---

Øa Øb

Ø b (shaft)

Dimension (mm) Standard Limit Standard Limit

AQ19002-002A

Gauge Measure with a slide caliper.


Issued 03-08


Lower roller Dimensions d

f

g

Øe

Øa

b

AQ19002-003A

Mark Øa b d Ø e (shaft)

Dimension (mm) Standard Limit Standard Limit Standard Limit Standard Limit

Mark

118 112 13 11 44 40 40 39

Ø e (ring) f g

Dimension (mm) Standard Limit Standard Limit Standard Limit

40 40.8 38 37.6 30.2 29.7

Gauge

170 150.5 - 151.5 105.7 - 106.3 44

2-

15°

13

R4

R5

6.5

2-

50

R3

4-

7

3°

° 1 .5

R6

AQ19002-033A


Issued 03-08


Track

Øf

Øf' d

c

Øe'

Øe

Øg'

Øg h

h

b

a

AQ19002-004A

Mark a b c d


Dimension (mm) Standard Limit Standard Limit Standard Limit Standard Limit

26 20 74 71.5 45 50 105 100

Mark Standard Ø e (ring) Limit Standard Ø f (ring) Limit Standard Ø g (shaft) Limit Standard h Limit Standard Ø e' (bushing) Limit Standard Ø f' (bushing) Limit Standard Ø g' (shaft) Limit

Dimension (mm) 41.3 40.3 24.5 23.8 23.8 23.2 154 150 41.26 40.26 24.5 25.2 24 23

Issued 03-08


DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES (MONO BOOM) 4 1

5 6 3

2

7 8 10

11

9 AQ19002-005A

1. Boom foot/Frame a b c

Ød

e

AQ19002-006A

Mark Standard Limit Standard b (boom) Limit Standard c (a - b) Limit Standard Ø d (shaft) Limit Standard Ø d (bushing) Limit

a (frame)


Dimension (mm) 400 410 399 397 1.0 to 3.5 Shims 60 59 60 61.5

Issued 03-08


2. Boom cylinder foot/Frame a b

c

Øe

Ød

AQ19002-007A

Mark Standard a (frame) Limit Standard b (cylinder) Limit Standard c (play) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit


3. Boom cylinder head/Boom

Øe

b

Ød

c

a AQ19002-008A

Mark Standard a (boom) Limit Standard b (cylinder) Limit Standard c (play) Limit Standard Ø d (shaft) Limit Standard Ø d (bushing) Limit



Issued 03-08


4. Dipper cylinder foot/Boom Mark

b

c

a

Øe

Dimension (mm)

Standard a (boom) Limit Standard b (cylinder) Limit Standard c (a - b) Limit Standard Ø d (shaft) Limit Standard Ø d (bushing) Limit

Ød

81 87 80 78 0.5 to 3.0 Shims 55 54 55 56.5

AQ19002-009A

5. Boom/Dipper Mark

c

a (boom) b (dipper)

Ød

Øe

c (play) b f

Ø d (shaft)

a Ø e (dipper) AQ19002-010A

Ø f (boom)

Dimension (mm) Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

184.5 187.5 184 182 0.5 to 1.1 Shims 60 59 60 61.5 45 Refer a and b

6. Dipper cylinder head/Dipper Mark

a b

Øe

Standard Limit Standard b (cylinder) Limit Standard c (a - b) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit

c

a (dipper)

Ød


AQ19002-011A


Issued 03-08


7. Bucket cylinder foot/Dipper Mark

Øe

Ød

b

c

a AQ19002-012A

Dimension (mm)

Standard a (dipper) Limit Standard b (cylinder) Limit Standard c (a - b) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit

76 82 75 73 0.5 to 3.0 Shims 50 49 50 51.5

Mark a (connecting Standard Limit rod)

Dimension (mm)

Standard Limit Standard c (play) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit

190 188 1.0 to 1.5 Shims 50 49 50 51.5

8. Connecting rod/Dipper c a

b (dipper)

b Øe a Ød

25 22

AQ19002-013A

9. Compensator/Bucket Ød

Mark

c

Øe b

191 197 190 188

Standard Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit

0.5 to 3.5 Shims 50 49 50 51.5

c (play)

a

Dimension (mm)

Standard a (bucket) Limit Standard b (compensator) Limit

AQ19002-014A


Issued 03-08


10. Connecting rod/Compensator/Bucket cylinder head Mark a (connecting rod) b (compensator)

c a f b

Øi

Øe Ød

Øh a

Dimension (mm) Standard Limit

25 22

Standard Limit

190 188

Standard Limit d (connecting Standard Limit rod)

1.0 to 1.5 Shims 71 73

Standard Limit Standard f (d - e) Limit Standard Ø g (shaft) Limit Standard Øh (compensator) Limit

70 68 1.0 to 2.0 Shims 55 54 55 56.5

c (play)

e (cylinder)

Øg Øg AQ19002-015A

Ø i (cylinder)

Standard Limit

55 56.5

11. Dipper/Bucket Mark

c

a (bucket)

Øg d

b (dipper)

Øf a

c (a - b)

b

d (bucket) Ø e (shaft) Ø f (dipper)

Øe AQ19002-016A


Ø g (bucket)

Dimension (mm) Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

210 216 190 188 1.0 to 3.5 Shims 19 11 50 49 50 51.5 50 51.5

Issued 03-08


DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES (CX75SR OFFSET BOOM) 4

8

7

3

1

6

2

7

5

9

AQ19002-017A

1. Base Boom/Offset boom c

b

a

Ød Øe AQ19002-018A

Mark a (boom) b (offset boom)


Standard Limit Standard Ø d (shaft) Limit Standard Ø d (bushing) Limit

c (a - b)


361 367 360 358 0.5 to 1.5 Shims 100 99 100 101.5

Issued 03-08


2.Base Boom/Offset cylinder/Rod h

a

b

d

e

c f

g i AQ19002-019A

Mark

Dimension (mm)

Standard a (frame) Limit b (offset cylin- Standard Limit der)

c (play) d (boom) e (rod)

71 77 70 68

Standard Limit

0.5 to 3.0 Shims

Standard Limit Standard

158 164 157

Limit

152

Mark


f (play) g (shaft)

0.5 to 3.0 Shims 55 54

h (bushing off- Standard set cylinder) Limit

55 56.5

Standard Limit

55 56.5

i (bushing rod)

3. Offset Boom/ Offset cylinder

c

b

a

Øe Ød

AQ19002-020A

Mark a (offset boom) b (offset cylinder)


71 77

Standard Limit

70 68

Standard Limit Standard d (shaft) Limit e (bushing off- Standard set cylinder Limit

c (play)


0.5 to 3.0 Shims 55 54 55 56.5

Issued 03-08


4. Offset Dipper/Rod Mark a (offset dipper)

c

b (rod) b

a c (a - b) Ø d (shaft)

c

Ød Øe

Ø e (bushing rod)


158 164

Standard Limit Standard Limit Standard Limit Standard Limit

157 155 0.5 to 3.0 Shims 55 54 55 56.5

AQ19002-021A

5. Offset arm/Offset Boom Mark a (offset dipper) b (offset boom)

b a

c (play) c

Ø d (shaft)

d e AQ19002-022A

Ø e (bushing offset boom)


281 287

Standard Limit

280 278

Standard Limit Standard Limit Standard Limit

0.5 to 1.5 Shims 100 99 100 101.5

6. Offset Dipper/ Dipper cylinder Mark a (offset dipper) b dipper cylinder)

a b c

d

c (a - b)

e

Ø d (shaft)

AQ19002-023A


Ø e (bushing dipper cylinder)


251 257

Standard Limit

250 248


0.5 to 3.0 Shims 60 59 60 61.5

Issued 03-08


7. Offset dipper/Dipper Mark a (offset dipper)

a b


Standard Limit Standard c (a - b) Limit Standard Ø d (shaft) Limit Ø e (bushing Standard Limit dipper)

b (dipper)

Ød

Øe

c AQ19002-024A

184.5 190.5 184 182 0.5 to 1.1 Shims 60 59 60 61.5

8. Dipper/Dipper cylinder Mark

a b

a (dipper) c

b (dipper cylinder)

Ød


Standard Limit Standard Ø d (shaft) Limit Ø e (bushing Standard arm cylinder) Limit

c (play)

Øe

81 87 80 78 0.5 to 3.0 Shims 50 49 50 51.5

AQ19002-025A

9. Dipper/Bucket cylinder Mark

a b

a (dipper) b (bucket cylinder)


c (play)

Ød


Øe

c

76 82 75 73 0.5 to 3.0 Shims 50 49 50 51.5

AQ19002-026A


Issued 03-08


DIMENSIONS AND WEAR LIMITS OF BLADE AND BLADE CYLINDER

10

11

12 AQ19002-027A

10. Blade/Blade cylinder Mark a (blade) b ( cylinder blade) Ød

Øe

c (play) d (shaft)

b a

c

e (bushing)


71 77 70 68


1.0 to 2.5 Shims 55 54 55 56.5

AQ19002-028A

11. Lower frame/Blade cylinder Mark a (frame) b (cylinder blade) Ød

b a

Øe

c



c (play)

76 82 75 73 3.0 to 4.5 Shims 55 54 55 56.5

AQ19002-029A


Issued 03-08


12. Lower frame/Blade Mark a (frame) b (blade) c (play) Ød

Øe d (shaft)

b a

e (bushing)

c

Dimension (mm) Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

69 75 65 63 3.0 to 5.0 Shims 45 44 45 46.5

AQ19002-030A


Issued 03-08


LIST OF SHIMS For Adjusting Attachment Gaps (Units: mm) Part No.

I.D.

O.D.

Shim Thickness

Material

KMV0650

30.2

50

0.4

SPCC

KMV0651

30.2

50

0.8

SPCC

KMV0652

30.2

50

1.6

SPHC

KMV0653

30.2

50

3.2

SPHC

KMV0654

30.2

50

4.5

SS00

KMV0655

30.2

50

6.0

SS00

KMV0912

32

45

0.4

SPCC

KMV0913

32

45

0.8

SPCC

KMV0914

32

45

1.2

SPCC

KHV0327

36

65

1.2

SPHC

KHV0316

36

70

1.2

SPHC

KHV0315

41

75

1.2

SPHC

KHV0324

41

80

1.2

SPHC

KHV0317

41

90

1.2

SPHC

KAV0058

43

90

1.6

SPHC

KHV0347

46

80

1.2

SPHC

KAV0180

46

80

1.6

SPHC

KAV0682

46

90

1.2

SPHC

KHV0299

46

100

1.2

SPHC

KHV0328

51

85

1.2

SPHC

KAV0160

51

85

1.6

SPHC

BHV1030

51

90

1.2

SPHC

BHV1031

51

90

2.6

SPHC

KHV0330

51

95

1.2

SPHC

KAV0813

51

100

1.2

SPHC

KAV1951

51

100

2.6

SPHC

KAV0061

51

101.6

1.6

SPHC

KHV0348

51

105

1.2

SPHC

KAV0805

51

120

1.2

SPHC

KAV0812

56

90

1.2

SPHC

KAV0558

56

100

1.2

SPHC

BHV1033

56

100

2.6

SPHC

KHV0298

56

105

1.2

SPHC

KAV0395

56

110

0.8

SPHC

KAV0060

56

110

1.6

SPHC

KAV0396

56

115

1.2

SPHC

KAV0427

56

120

1.2

SPHC

KMV0771

60.5

76

1.2

SPHC

KAV0161

61

90

1.6

SPHC


Issued 03-08

Copyright © 1002-44 (Units: mm) Part No.

I.D.

O.D.

Shim Thickness

Material

KAV0811

61

110

1.2

SPHC

KNV0230

61

110

1.2

SPHC

KAV0059

61

110

1.6

SPHC

KHV0286

61

120

1.2

SPHC

KAV0801

61

130

1.2

SPHC

KMV0942

61

140

3.2

SPHC

KMV1246

61

160

1.2

SPHC

KMV0693

65.5

90

1.2

SPHC

KNV0538

66

100

1.2

SPHC

KLV0034

66

110

1.2

SPHC

KNV0535

66

120

1.2

SPHC

KMV0122

66

130

1.2

SPHC

KHV0273

66

150

1.2

SPHC

KHV0458

66

170

1.2

SPHC

KNV0696

71

110

1.2

SPHC

KNV0539

71

130

1.2

SPHC

KRV0823

71

130

1.2

SPHC

KMV0144

71

135

1.2

SPHC

KMV0145

71

135

2.6

SPHC

KMV0774

71

150

1.2

SPHC

KMV0775

71

150

2.6

SPHC

KMV0941

71

150

3.2

SPHC

KNV0189

71

150

1.2

SPHC

KRV1176

76

130

1.2

SPHC

KRV1177

76

140

1.2

SPHC

KRV1584

76

140

1.2

SPHC

KHV0169

76

140

1.2

SPHC

KNV0534

76

160

1.2

SPHC

KRV2264

76

180

1.2

SPHC

KAV0776

77

120

1.2

SPHC

KSV0141

78

170

1.2

SPHC

KSV0142

78

170

2.6

SPHC

KSV0143

78

170

3.2

SS00

KAV0095

81

105

1.6

SPHC

KLV0170

81

110

1.2

SPHC

KRV1197

81

140

1.2

SPHC

KRV0822

81

150

1.2

SPHC

KRP1350

81

150

2.6

SPHC

KLV0035

81

170

1.2

SPHC


Issued 03-08


I.D.

O.D.

Shim Thickness

Material

KSP0408

81

200

1.2

SPHC

KSP0409

81

200

2.6

SPHC

KBV0122

82

120

3.2

SS00

KBV0123

82

120

4.5

SS00

KBV0124

82

120

6.0

SS400

KBV0373

82

180

1.0

SPCC

KRV1178

86

130

1.2

SPHC

KRV1585

86

150

1.2

SPHC

KHV0170

86

150

1.2

SPHC

KBV0389

87

210

1.0

SPCC

KBV0390

87

210

1.6

SPCC

BHV1030

90

51

1.2

SPHC

KBV0837

91

135

1.2

SPHC

KSV0477

91

145

1.2

SPHC

KSP0411

91

145

2.6

SPHC

KMV0121

91

159

1.2

SPHC

KBV0769

91

160

1.2

SPHC

KSP0269

91

160

2.6

SPHC

KBV0764

91

165

1.2

SPHC

KRV0559

91

180

1.2

SPHC

KRV1180

91

190

1.2

SPHC

KSP0412

91

200

1.2

SPHC

KSP0413

91

200

2.6

SPHC

KBV0381

92

180

1.0

SPCC

KBV0382

92

180

1.6

SPCC

KBV0383

92

180

2.0

SPCC

KBV0384

92

180

3.2

SS00

KBV0377

92

220

1.0

SPCC

KBV1749

96

140

1.2

SPHC

KNV0468

96

150

1.2

SPHC

KSP0828

96

150

1.2

SPHC

KBV1629

96

170

1.2

SPHC

KBV0361

97

250

1.0

SPCC

KBV0362

97

250

1.6

SPCC

BHV1032

100

56

1.2

SPHC

KSV0478

101

160

1.2

SPHC

KSP0415

101

160

2.6

SPHC

KSP0416

101

180

1.2

SPHC

KSP0417

101

180

2.6

SPHC

KBV0474

101

219

1.2

SPHC


Issued 03-08


I.D.

O.D.

Shim Thickness

Material

KBV0369

102

210

1.0

SPCC

KSV0138

103

190

1.2

SPHC

KSV0139

103

190

2.6

SPHC

KSV0140

103

190

3.2

SS00

KSV0135

103

213

1.2

SPHC

KSV0136

103

213

2.6

SPHC

KSV0137

103

213

3.2

SS00

KSP0827

106

170

1.2

SPHC

KHV0190

111

150

1.2

SPHC

KSP0418

111

180

1.2

SPHC

KSP0419

111

180

2.6

SPHC

KTV0533

111

190

1.2

SPHC

KSV0476

111

230

1.2

SPHC

KBV0214

112

150

6.0

SS400

KBV0215

112

150

9.0

SS400

KBV0357

112

270

1.0

SPCC

KHV0193

121

155

1.2

SPHC

KMV1517

121

220

0.4

SPHC

KMV1518

121

220

0.6

SPHC

KMV1519

121

220

0.8

SPHC

KHV0296

121

230

1.2

SPHC

KTV0534

121

250

1.2

SPHC

KWV0101

131

170

1.2

SPHC

KSV0839

131

200

1.2

SPHC

KHV0287

131

240

1.2

SPHC

KTV0850

141

225

1.2

SPHC

KHV0297

141

240

1.2

SPHC

KHV0288

151

300

1.2

SPHC

KUV0080

171

280

1.2

SPHC


Issued 03-08


For Adjusting Attachment Gaps (for Boom Foot)

R O.D I.D

H

000-6-10-02-02a1

Part No.

I.D.

O.D.

R

H

Shim Thickness

Material

KNV1132

76

160

100

30

1.2

SPHC

KRV2390

91

190

115

30

1.2

SPHC

KBV1441

101

220

130

30

1.2

SPHC

KBV1748

101

230

135

30

1.2

SPHC

KSV1805

111

240

140

30

1.2

SPHC


Issued 03-08


R O.D I.D

H

000-6-10-02-02b1

Part No.

I.D.

O.D.

R

H

Shim Thickness

Material

KSV1930

111

240

140

30

1.0

Urethone

KSV11380

111

240

140

30

2.0

Urethone

KSV1931

116

240

140

30

1.0

Urethone

KSV11390

116

240

140

30

2.0

Urethone

KTV10730

121

245

150

50

2.0

Urethone

KTV10740

121

245

150

50

1.0

Urethone

KTV10750

121

260

150

50

2.0

Urethone

KTV10760

121

260

150

50

1.0

Urethone

KWV0097

141

280

160

50

1.0

Urethone

KWV10510

141

280

160

50

2.0

Urethone

KWV0096

141

300

180

50

1.0

Urethone

KWV10500

141

300

180

50

2.0

Urethone

KUV10150

141

300

170

30

1.0

Urethone

KUV10160

141

300

170

30

2.0

Urethone

KUV10130

151

300

170

30

1.0

Urethone

KUV10140

151

300

170

30

2.0

Urethone


Issued 03-08


SPECIAL TORQUE SETTINGS CX75SR No.

Component

Screw

Wrench (mm)

Torque setting

1*

Travel motor and reduction gear assembly

M16

24

267-312 Nm (197-230 lb-ft)

2*

Drive sprocket

M14

22

173-202 Nm (127-149 lb-ft)

3*

Idler wheel

M10

17

63-73 Nm (46-54 lb-ft)

4*

Upper roller

M16

24

267-312 Nm (197-230 lb-ft)

5*

Lower roller

M20

30

521-608 Nm (384-448 lb-ft)

6

Shoe bolt

M14

22

267-312 Nm (197-230 lb-ft)

7

Counterweight

M24

36

850-992 Nm (627-658 lb-ft)

8

Turntable bearing (lower frame)

M16

24

280-322 Nm (206-237 lb-ft)

9

Turntable (swing frame)

M16

24

280-322 Nm (206-237 lb-ft)

10 *

Swing unit

M16

24

273-318 Nm (201- 234 lb-ft)

11 *

Engine (engine mount)

M16

24

265-314 Nm (196-231 lb-ft)

12 *

Engine bracket

M10

17

64-74 Nm (47-54 lb-ft)

Radiator

M12

19

64-74 Nm (47-54 lb-ft)

M10

17

63-73 Nm (47-54 lb-ft)

M12

10 Hexagon socket head

13 14 * 15 * 16 *

Hydraulic pump

109-127 Nm (80-94 lb-ft)

Hydraulic reservoir

M12

19

69-79 Nm (51-58 lb-ft)

17

Fuel reservoir

M10

17

36-44 Nm (26-32 lb-ft)

18 *

Control valve

M16

24

267-312 Nm (197-230 lb-ft)

M12

19

88-107 Nm (65-79 lb-ft)

19 *

Hydraulic swivel

M12

19

88-107 Nm (65-79 lb-ft)

20

Cab

M16

24

71-86 Nm (52-63 lb-ft)

21

Battery

M10

17

64-74 Nm (47-54 lb-ft)

NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).


Issued 03-08


16

21

17

13

18

20 11 12

7 14 15 10

19

10 6

1 7 2 5 4

8,9

3

1 , 2 2

FRONT

3 , 4 , 5 ,

1

7

6

3 4

5

6

7 AQ09002-001


Issued 03-08


8 , 9 , 10

11 , 12 ,13

10

9

8 11 12 16

14 , 15

11 12

17

13

17

15 14

17

16

17 18

19

19

18

20

21 21

20

AQ09002-002


Issued 03-08


SPECIAL TORQUE SETTINGS CX80 No.

Component

Screw

Wrench (mm)

Torque setting

1*

Travel motor and reduction gear assembly

M16

24

267-312 Nm (197-230 lb-ft)

2*

Drive sprocket

M14

22

173-202 Nm (127-149 lb-ft)

3*

Idler wheel

M10

17

63-73 Nm (46-54 lb-ft)

4*

Upper roller

M16

24

267-312 Nm (197-230 lb-ft)

5*

Lower roller

M20

30

521-608 Nm (384-448 lb-ft)

6*

Front guard

M16

24

267-312 Nm (197-230 lb-ft)

7

Shoe bolt

M14

22

220-270 Nm (162-199 lb-ft)

8

Counterweight

M24

36

850-992 Nm (627-658 lb-ft)

9

Turntable (swing frame)

M16

24

252-283 Nm (186-209 lb-ft)

10 *

Swing unit

M16

24

273-317 Nm (201-234 lb-ft)

11 *

Engine (engine mount)

M16

24

265-313 Nm (196-231 lb-ft)

12 *

Engine bracket

M10

17

64-74 Nm (47-54 lb-ft)

Radiator

M10

17

36-44 Nm (26-32 lb-ft)

M10

63-73 Nm (47-54 lb-ft)

M12

17 Hexagon socket head

Hydraulic reservoir

M12

19

69-78 Nm (51-57 lb-ft)

17 *

Fuel reservoir

M12

19

98-108 Nm (72-80 lb-ft)

18 *

Control valve

M12

19

53-64 Nm (39-47 lb-ft)

19 *

Hydraulic swivel

M10

17

63-73 Nm (46-54 lb-ft)

13 14 * 15 * 16 *

Hydraulic pump

109-126 Nm (80-93 lb-ft)

NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).


Issued 03-08


FRONT

FRONT


Issued 03-08


FRONT


Issued 03-08


MACHINE OVERALL DIMENSIONS MONO BOOM SPEC (CX75SR) 1. Standard Arm (1.71 m) NOTE: Numbers are subject to change without notice due to design change or other reasons. The figures give values that include the shoe lug height (20 mm (0.79 in)

2. Long Arm (2.12 m)


Issued 03-08


MONO BOOM SPEC (CX80) 1. Standard Arm (1.71 m) NOTE: Numbers are subject to change without notice due to design change or other reasons. The figures give values that include the shoe lug height (20 mm (0.79 in)

2. Long Arm (2.12 m)


Issued 03-08


OFFSET BOOM SPEC (CX75SR) 1. Standard Arm (1.75 m)


Issued 03-08


NOTES .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... ....................................................................................................................................................................................


Issued 03-08

Copyright ©

Section 2000

CNH

Lep SM75SR2000-0EN

Copyright © 2008 CNH France S.A. Printed in France August 2008

2000

REMOVAL AND INSTALLATION OF THE ENGINE

Copyright © 2000-2

TABLE OF CONTENTS ENGINE.................................................................................................................................................................... 3

Lep SM75SR2000-0EN

Issued 08-2008

Copyright © 2000-3

ENGINE 100 11 6

8 744

7

4.9 to 5.9 Nm

9

8.8 to 9.8 Nm 8.8 to 9.8 Nm

133 2

B

155

144

200 21 222

X3 X3

166 177

68.7 to 98.1 Nm

199

18 5

200 X2

4 3 8.8 to 9.8 Nm

8

2

C

X2

655 666 100 11

1

122

4 X4

288 322

399

31

63.8 to 73.6 Nm

244 255 266 X4

264.9 to 313.9 Nm

288

63.8 to 73.6 Nm

299 244 255 266 277 233

264.9 to 313.9 Nm

A 4.9 to 5.9 Nm

4.9 to 5.9 Nm

522

4.9 to 5.9 Nm

X2 2

X2

555

533

500 51

4.9 to 5.9 Nm

599

5

61 599 4.9 to 5.9 Nm 622 30 63 64 655 66

244 255 266 277 288

233 288 300

63.8 to 73.6 Nm

X4

677

688

264.9 to 313.9 Nm

1. Coat the thread of sym (24) (30) (32) (45) with loctite 262 or equivalent after removing any oil film and fasten by tightening torque. 2. apply packing liquid (50) to the connection of radiator hose after removing any oil film and fasten by tightening torque.

Lep ASM-17-11-002EN

X4

X4

699 700 233 244 255 266 277 288

288 322

722

71

733 63.8 to 73.6 Nm

63.8 to 73.6 Nm

KAH11280-E02

3. Tighten up the clip; jubilee from the direction shown on the drawing. 4. Arrow mark ( ) in the labels (69) represent the top.

Issued 08-2008

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

Air inlet pipe (1) Hose clamp (2) Radiator stay (1) Bolt (6) Air hose (1) Vacuum indicateur (1) Cushion seal (1) Radiator (standard) assy (1) Label (1) Rubber hose (L = 800) (1) Corrugated tube 13 x 8 00 (1) Hose band (3) Jubilee clip 50 - 65 (1) Hose clamp (1) Air hose (1) High strength nut M8 (3) Spring washer 8 (3) Exhaust pipe (1) Clamp (1) Diesel engine dom (1) Elastic rubber (8) High strength bolt M16 x 130 (4) High strength washer 16 (4) Plate (4) Nut (4) Bond 262 (-) Engine supt (1) Bolt M10 x 25 (10) Engine supt (1) Bolt M10 x 30 (8) Bracket (1) Cushion seal (1) Hose clamp (1) Cushion seal (1) Reserve tank (1) Harness band L = 250 (1) Rubber hose (L = 900) (1) Muffler (1) U bolt M8 (2) Franged nut M8 (8) Hose band (1) Muffler bracket (1) High strength bolt M10 x 35 (3) High strength washer 10 (3) Tube L = 700 Bolt M8 x 25 (1) Clamp M8 (1) Liquid packing (-) Hose clamp 38 - 50 (2) Jubilee clip 58 - 75 (1) High strength bolt M8 x 45 (2) Plain washer 8 (2) Seal retainer (2) Cushion seal (1) Bolt M10 x 20 (2) Bracket (1) Jubilee clip 68 - 85 (3) Air hose (1) Air hose (1) Bracket (1) Bolt M8 x 20 (2) Air cleaner (1) Bolt M6 x 16 (2) Holder (1) Engine supt (1) Hose band (1) Rubber hose L = 600 Engine supt rf (1) Cushion seal (1) Acoustic insulation (1) Blot M12 x 30 (4) Radiator (standard) assy (1)

Lep ASM-17-11-002EN

D

X2 2

4 333

344

366

355

B

8.8 to 9.8 Nm

400 41 X8

422 433 444 288 455 46 63.8 to 73.6 Nm

477

C

366 344 722

D KAH11280-E02b

Issued 08-2008

3001

Copyright ©

Section 3001 REMOVAL AND INSTALLATION OF THE FUEL TANK

CNH

Lep SM75SR3001-0EN


Copyright © 3001-2

TABLE OF CONTENTS FUEL TANK ............................................................................................................................................................. 3

Lep SM75SR3001-0EN

Issued 08-2008

Copyright © 3001-3

FUEL TANK See detail A

2

1 x2 7 x2 7

2 12

8 11 3

x2x2 4 5

6

x2 8 7

9

x2 10

13

See detail B

21 x2 7

22 23

25 14 22

See detail C

3

20

14

6

24

x2x2 15 16 17

18

19 KAH10760-D00

NOTE: 1. The specifications of fuel tank refer to the bollows. Tank capacity: 100L Limited inclined angle: 35° 2. Do not cover the drill hole.

Lep AST-15-11-003

Issued 08-2008

Copyright © 3001-4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.

Fuel tank Bracket Tank belt Hige strength washer High strength nut Bracket Sems bolt M10x25 Hose band Rubber hose Sems bolt M10x16 Drain cock Plate Filter Bracket High strength bolt M10x40 Hige strength washer Bond 262 Sponge cushion Sponge cushion Sensor cover Bracket Rubber plate Rubber plate Rubber plate Rubber plate High strength bolt Tank frange Rubber packing Fuel sensor Non-asbestos packing Liquid packing Pan screw hd M5x12 High strength bolt High strength washer Spacer Rubber cushion High strength bolt M10x65

12

33 34 35 36

A

21

36

35 34 37

B

x8 26

5.9 to 6.9 Nm

27 28 29 30 31 x5 32

C

Lep AST-15-11-003

KAH10760-D00

Issued 08-2008

4001

Copyright ©

Section 4001 ELECTRICAL AND ENGINE FUNCTIONS, & SERVICE SUPPORT

CNH



Copyright © 4001-2

TABLE OF CONTENTS CNH-EST DIAGNOSTIC TOOL ..................................................................................................................................... 3 Monitor Display ...................................................................................................................................................... 4 Engine Control ....................................................................................................................................................... 6


Issued 03-08

Copyright © 4001-3

CNH-EST DIAGNOSTIC TOOL

The EST (Electronic Service Tool) system allows diagnoses on machines and engines by detecting the operating parameters of electronic control components (control units, sensors etc). It is also capable of reading fault codes. To use this tool, please refer to the book provided during the training sessions.


Issued 03-08

Copyright © 4001-4

Monitor Display 1. Monitor Switch Panel

1.Fuel gauge

4.Overheat

10.Wiper switch

2.Coolant temperature gauge

5.Abnormal engine oil pressure

11.Washer switch

3.Hour meter

6.Low fuel

12.Working light switch

7.Battery charge error

13.High speed travel switch

8. 9.Glow (Preheat) Indicator


Issued 03-08

Copyright © 4001-5

2. List of Functions

Functions 1

Remarks

Engine Start-up Control Engine Start-up Circuit

2

Monitor Output Control

3

Monitor Display Control

4

See page 6 2.1

Throttle control

See page 8

2.2

One-touch idling

See page 10

2.3

EGR cut control

See page 11

3.1

2-speed travel

See page 13

3.2

Swing brake

See page 14

3.3

Travel alarm

See page 15

3.4

Working light

See page 16

3.5

Windshield wiper/washer

See page 17

3.6

Power cut delay

See page 19

4.1

Overheat warning

See page 20

4.2

Engine oil pressure warning

See page 22

4.3

Low fuel warning

See page 23

4.4

Battery charging warning

See page 24

4.5

Glow timer (auto)

See page 25

4.6

Hour meter

Gate lock Horn Radio

AM/FM

Interior light 4

Heater

5

Air Conditioner (optional)

See Air Conditioner

6

Combined Line for Breaker and Crusher (optional)

See Hydraulic Circuit

Interference Prevention System

See Interference Prevention System

7


Issued 03-08

Copyright © 4001-6

Engine Control 1. Engine start-up control [1] Power supply (key switch at ON position) 1) Battery relay is energized. 2) Power is supplied to the initial excitation port (IG) in the alternator. (The alternator does not generate electricity until the input signal is recognized). 3) Power is supplied to the monitor to initiate operation. [2]

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

[3]

Low-temperature start-up feature / preheat (key switch at HEAT or at ST) 1) The heat relay is also energized during cranking (key switch at ST) to supply power to the air heater. This is to maintain the temperature achieved through manual preheating.


Issued 03-08

Copyright ©

4001-7

2. Engine Start-up Circuit BATTERY

B

G1 G2 ACC C M

1.25G 505

0.85BrW 270 OR 851

VW 170

1.25LW 180

LIMIT (GATE) SWITCH

1.25GR 185

C

B

VW 170

SAFTY RL.

1.25B 750

0.85BrR 51

0.85GrR 01

FUSE BOX

0.85W 160

0.85GrR 010

L

YR 852

R

E

B

ST

0.85GrR 009

KEY SW.

HEAT A OFF ACC ON ST

60R 001

B 707

5WR 009 8R 030

101

0.85LgR g 500

FUSE KEY SW.

5R 102

LOCK

0.85VR 195

SOLENOID

GW 225

0.85PW 230

M

STARTER MOTOR

0.85LgR g 500

LEVER

LgW g 175 60R 001

FUEL PUMP

5L 021

GLOW TIMER RL.

0.85LgR g 501 0.85LgR 501

GLOW PLUG

OPTION

OPTIONAL POWER

AUX.

1.25B 700

GR 255

GR 252 GW 225 GR 250 1.25WR 200 LgW g 175 0.85BrR 190 1.25GR 185 1.25LW 180 VW 170 0.85BrW 270 0.85W 160 R 150 VR 196 R 151

G 022 0.85WR 290 0.85LgR g 504 0.85GrR 011

0.25WR 520 0.858Br 510

ENG.

WATER TEMP. SENSOR

M

FUEL FEED PUMP

OPTION LINE (KNOB SW.)

TRAVEL MODE

TRAVEL ALARM SWING BRAKE

AIR-CON.

HORN WIPER/WASHER LAMP (SWING) LAMP (CAB.BOOM) LEVER LOCK THROTTLE MOTOR

MONITOR BACK UP AIR-CON BACK LIGHT BACK UP AIR-CON

GLOW LAMP KEY. ACC

KEY. ST

KEY. M

BATTERY RL

BATTERY CHARGE

0.85PW 230

0.85Y 310

2B 700

2B 600

600 700

255

151

011

520 510

Issued 03-08


0.85LgR g 500

ALTERNATOR

0.85B 753

0.85RW 120

BATTERY RL.

1.25GrR 330 3Y 331

G 022

1.25WR 200 3Y 330

0.85BG G04

8R 105

60R

0.85Br 510 1

0.85BrR 190 5WR 003

R 150 1.85G 505

0.85WR 290 0.85WR 520 0.85B 779

RELAY R11 STARTER CUT 8R 030

8B 797

1.25SR 102

60R 100 60B 799

8R 106

3B 767

GR 255

5WR 020

AO28002-001a

Copyright © 4001-8 [1] Throttle control 1) Configuration IDLING POWER SUPPLY 24V

MONITOR

THROTTLE VOLUME

ONE-TOUCH IDLING SWITCH

CONTROL DEVICE

IDLING SPRING GEAR

DC MOTOR

POTENTIOMETER

GOVERNOR LEVER

PULL CABLE

SPRING CHAMBER IDLING ADJUSTMENT SCREW

RACK

PULL SIDE L/S

THROTTLE MOTOR RETURN SIDE L/S

STROKE = 28mm (1.10 in) NOTE: WITH KEY SWITCH ON AND THROTTLE VOLUME AT FULL, SECURE BY FIRST FASTENING RETURN SIDE L/S: OFF WITH NUT (A) FOR 4 TURNS (APPROX. 5.0 mm 0.19 RETURN SIDE STOP in), THEN AN TIGHTENING ADDITIONALLY WITH NUT (A) AND (B). PULL SIDE L/S: OFF

PULL SIDE L/S: ON RETURN SIDE L/S: ON

PULL SIDE STOP HIGH-IDLING

PULL SIDE L/S: OFF

POWER SUPPLY 24V THROTTLE VOLUME

RETURN SIDE L/S: ON

OPERATION THROUGH THROTTLE VOLUME

MONITOR ONE-TOUCH IDLING SWITCH

CONTROL DEVICE

DC MOTOR

THROTTLE MOTOR

HIGH-IDLING ADJUSTMENT SCREW

AO28002-002A

Note:The idling and the high-idling positions for the engine governor are pre-adjusted by the engine supplier before delivery.


Issued 03-08

Copyright © 4001-9 1) Operational Description 1) When the power is supplied to the throttle motor, the control device compares the throttle volume signal and the potentiometer signal. It then outputs a signal to the DC motor to move the rack to the target position set by the throttle volume. 2) The DC motor then makes a normal or reverse rotation according to the signal received from the control device. 3) The output from the DC motor will be transferred to the reduction gears via the rack. The rack rotates the governor lever by allowing the PULL cable to stroke to increase/decrease the engine revolutions. 4) The potentiometer signals interlock with the rack. When the signal coincides with the throttle volume signal, the control device will stop the output of the command signal for motor rotation. 5) The rack strokes are controlled by the Pull side L/S and the Return side L/S.

PULL SIDE L/S: ON, RETURN SIDE L/S: ON

STROKE 28 mm (1.10in)

ENGINE RPM HIGH-IDLING 2150 RPM SPRING BEND AREA

POTENTIOMETER VOLTAGE

PULL SIDE L/S: OFF, RETURN SIDE L/S: ON

CABLE SLACK AREA

PULL SIDE L/S: OFF, RETURN SIDE L/S: ON

IDLING 1100 RPM

6) When the working tension on the throttle motor reaches 15 kgf or above, the overload protection circuit will be initiated to prevent the DC motor seizure. Note: When the limit switch becomes damaged by an open circuit or a short circuit, the conditions will be as follows: • Damage by open circuit: The DC motor alters the engine rpm in response to the throttle volume. The current continues to flow to the DC motor at the time of maximum engine rpm and during idling. The overload is thus detected and the output to the DC motor will be stopped. • Damage by short circuit: The rack does not move to the side where a short circuit has taken place in the limit switch. If the limit switch has a short circuit on the Pull side, the rack can only move toward the Return side from the location it was in when the short circuit took place (to the limit switch on the Return side). If the limit switch had a short circuit on the Return side, the rack can move to the Pull side only (to the limit switch on the Pull side).


Issued 03-08

Copyright © 4001-10 [2]

One-touch idling POWER SUPPLY 24V

MONITOR

THROTTLE VOLUME


GND GND

CONTROL DEVICE

DC MOTOR

PULL CABLE

GOVERNOR LEVER SPRING CHAMBER

IDLING ADJUSTMENT SCREW

THROTTLE VOLUME POWER SUPPLY MONITOR CONTROL DEVICE

5V


GND GND

DC

COMMAND SIGNAL FOR MOTOR ROTATION

MOTOR

GND

MONITOR POWER SUPPLY OFF=0 V

ON=24 V

OFF=24 V ONE-TOUCH IDLING SWITCH

ON=0 V OFF=5 V

MONITOR OUTPUT

ON=0 V

RESET

PROGRAMMED POSITION FOR THROTTLE VOLUME THROTTLE POSITION

IDLING POSITION AO28002-004A

Note:When the motor output is ON, the control device moves the rack to the idling position regardless of the throttle volume location.


Issued 03-08

Copyright © 4001-11 [3]

EGR cut control The purpose of EGR cut control is to reduce nitrogen oxide (NOx), which occurs easily at high combustion temperatures, by opening EGR and partially mixing the exhaust gas with the suction air to reduce the combustion temperature. 1) Operation explanation 1) When the coolant temperature reaches 60°C or higher, the EGR cut relay is turned ON. (When the coolant temperature is less than 60°C EGR is closed. However, note that there is a hysteresis setting for the opening side at 60°C and the closing side at 55°C and EGR will not close immediately even if the coolant temperature drops below 60°C) 2) When the EGR cut relay is ON, the sensor reads the boost pressure and engine speed and the following graph operations are performed.

15

EGR OPEN

Boost Pressure (KPa)

EGR OPEN

EGR OPEN

EGR OPEN EGR CLOSE

EGR CLOSE

EGR CLOSE EGR CLOSE

4 0

0

1250

1400 Engine Speed (min

1820 1850 -1)

AQ28002-024A

When the boost pressure is less than 4 kPa, EGR opens when the engine speed is 1850 min-1 or higher, and EGR closes when the engine speed is less than 1820 min-1.


15

EGR OPEN

EGR OPEN

EGR OPEN

EGR OPEN EGR CLOSE

EGR CLOSE

EGR CLOSE

EGR CLOSE

4 0

0

1250

1400 Engine Speed (min -1)


1820 1850 AQ28002-025A

Issued 03-08

Copyright © 4001-12 When the boost pressure is 15 kPa, EGR opens when the engine speed is 1400 min-1 or higher, and EGR closes when the engine speed is less than 1250 min-1. *:Once EGR is open, it does not close until the engine speed reaches a level where it is set to close.Conversely, once EGR is closed, it does not open until the engine speed reaches a level where it is set to open.

15

EGR OPEN


EGR OPEN

EGR OPEN

EGR OPEN

EGR CLOSE EGR CLOSE

EGR CLOSE EGR CLOSE

4 0

0

1250

1400

1820 1850

Engine Speed (min -1)

AQ28002-026A

When the boost pressure is 4 kPa or higher but less than 15 kPa, EGR opens when the engine speed is 1850 min-1 or higher, and EGR closes when the engine speed is less than 1250 min-1. *:Once EGR is open, it does not close until the engine speed reaches a level where it is set to close.Conversely, once EGR is closed, it does not open until the engine speed reaches a level where it is set to open.

15

EGR OPEN


EGR OPEN

EGR OPEN

EGR OPEN EGR CLOSE

EGR CLOSE

EGR CLOSE EGR CLOSE

4 0

0

1250

1400 Engine Speed (min -1)


1820 1850 AQ28002-027A

Issued 03-08


3. Monitor Output Control [1] 2-Speed travel 1) Configuration

MONITOR

RELAY SOLENOID

TRAVEL CHANGEOVER SWITCH

2) Operation

TRAVEL CHANGEOVER SWITCH MONITOR OUTPUT

RESET LIGHTS ON LIGHTS OUT

LED DISPLAY LAMP CHECK

LAMP CHECK

• If the key switch is turned ON again after it was turned OFF, the low travel speed is always selected.


Issued 03-08

Copyright © 4001-14 [2]

Swing brake 1) Configuration

MONITOR

KEY.M

KEY SWITCH

RELAY

SWING RIGHT PRESSURE SWITCH SWING LEFT PRESSURE SWITCH

ATTACHMENT PRESSURE SWITCH SOLENOID

2) Operation

POWER CUT DELAY

KEY.M (KEY SWITCH ON) SWING PRESSURE SWITCH

ATTACHMENT PRESSURE SWITCH

MONITOR OUTPUT

SWING BRAKE SOLENOID BRAKE ON

BRAKE ON

• The brake will go ON 5 s after the attachment switch is turned OFF. • The brake will go ON 3 s after the power cut delay.


Issued 03-08

Copyright © 4001-15 [3]

Travel alarm 1) Configuration

MONITOR

TRAVEL ALARM TRAVEL PRESSURE SWITCH

2) Operation

TRAVEL PRESSURE SWITCH

MONITOR OUTPUT

• The travel pressure switch will also be turned ON through steering/pivot turn operations, thus activating the alarm.


Issued 03-08

Copyright © 4001-16 [4]

Working light 1) Configuration RELAY

SWING WORKING LIGHT

MONITOR REAR LIGHT LAMP

RELAY

WORKING LIGHT SWITCH

BOOM WORKING LIGHT CAB WORKING LIGHT

REAR LIGHT LAMP

REAR LIGHT LAMP

CRANE MONITOR

AIR CONDITIONER PANEL AO28002-010A

2) Operation

WORKING LIGHT SWITCH

MONITOR OUTPUT

RESET LIGHTS ON

WORKING LIGHT REAR LIGHT

LIGHTS ON LIGHTS OUT

RESET

• If the key switch is turned ON again after it was turned OFF, the working lights and the rear lights will be reset.


Issued 03-08

Copyright © 4001-17 [5]

Windshield wiper / washer 1) Configuration POINT OF CONTACT FOR OPERATION

WIPER MOTOR

IGN

IGN

MONITOR

M RELAY

WIPER SWITCH

GND

GND OUT 1

INT LED

GND

CNT LED

IGN

RELAY

GND

WASHER MOTOR

M OUT 2

WASHER SWITCH

GND

GND

GND

GND

AO28002-011A

2) Operation 1) Wiper

WIPER SWITCH

WIPER OUTPUT OUT 1

LIGHTS ON

INT LED DISPLAY (INTERMITTENT) CNT LED DISPLAY (CONTINUOUS)


LIGHTS OUT

LIGHTS ON

LAMP CHECK LIGHTS OUT

LIGHTS ON

LIGHTS OUT

Issued 03-08

Copyright © 4001-18 2) Windshield wiper / washer

WIPER SWITCH

WIPER OUTPUT OUT 2

WIPER OUTPUT OUT 1

• The LED for intermittent/continuous movements will not be turned ON when the windshield washer switch is turned ON.


Issued 03-08

Copyright © 4001-19 [6]

Power cut delay 1) Configuration

MONITOR KEY SWITCH

BATTERY BATTERY RELAY

KEY. M

2) Operation

KEY. M KEY SWITCH ON

MONITOR OUTPUT

• Due to the overcurrent protection circuit provided in the monitor output, the monitor will not be damaged in the event that a short circuit occurs in the harness or in the battery relay coil.


Issued 03-08


4. Monitor Display Control [1] Overheat warning 1) Configuration

MONITOR COOLANT TEMPERATURE GAUGE THERMO-SENSOR (COOLANT) THERMO-SWITCH (COOLANT)

OVERHEAT SIGNAL

THERMO-SWITCH (OIL)

Thermo-sensor specifications for analog meter Temperature (°C {°F})

50 {122}

80 {176}

100 {212}

120 {248}

Resistance (ohm)

153.9

32.3

18.4

16.1

Thermostat switch (coolant) specifications Switch ON (°C {°F})

105 {221}

Thermostat switch (oil) specifications


Switch ON (°C {°F})

98 {208.4}

Switch OFF (°C {°F})

91 {195.8}

Issued 03-08

Copyright © 4001-21 2) Operation

OVERHEAT SIGNAL LAMP CHECK OVERHEAT WARNING LED BUZZER CHECK BUZZER

• When the overheat signal falls 1V or below, the monitor recognizes this as the switch being ON and turns the LED on. Therefore, even when the signal line is removed, the LED will still be turned ON.


Issued 03-08

Copyright © 4001-22 [2]

Engine oil pressure warning 1) Configuration

MONITOR

ENGINE OIL PRESSURE SWITCH

CRANKING SIGNAL KEY. ST

Pressure switch

0.029 MPa {4.2 psi} or less

2) Operation

IGN

KEY ST (CRANKING)

ENGINE OIL PRESSURE SWITCH LAMP CHECK

ENGINE OIL PRESSURE WARNING LED BUZZER CHECK BUZZER

• Even if a warning is requested, the buzzer will not be activated until the key switch signal (cranking signal) is received.


Issued 03-08

Copyright © 4001-23 [3]

Low fuel warning 1) Configuration

FUEL GAUGE

MONITOR

FUEL SENSOR UNIT FUEL SENSOR

FUEL THERMISTOR

Fuel sensor specifications Fuel remaining Sensor resistance (ohm)

Empty

1/2

Full

90

38

10

FUEL

EMPTY

2) Operation

IGN LOW FUEL WARNING SIGNAL (TERMISTOT) LAMP CHECK

FUEL REMAINING WARNING LED BUZZER CHECK

BUZZER

• When the thermistor resistance falls to 37 ohm or below, the monitor recognizes this as the signal being ON and turns on the LED.


Issued 03-08

Copyright © 4001-24 [4]

Battery charge warning 1) Configuration

MONITOR

ALTERNATOR BELOW 6V

CRANKING SIGNAL KEY. ST

2) Operation

IGN

KEY. ST (CRANKING)

ALTERNATOR SIGNAL LAMP CHECK

BATTERY CHARGE WARNING LED BUZZER CHECK

BUZZER

• Even if a warning is requested, the buzzer will not be activated until the key switch signal (cranking signal) is received. • When the alternator signal falls below 6V, the monitor turns the warning ON.


Issued 03-08

Copyright © 4001-25 [5]

Glow timer (auto) 1) Configuration

KEY SWITCH OFF ON

ST PREHEAT LAMP

3

1

A BATTERY DC24V

B

GLOW PLUG TIMER

5 GLOW PLUG

4

6 TEMPERATURE SENSOR

AO28002-022A

2) Operation

ST

ST

KEY SWITCH

ON

ON

ON

OFF

LAMP

ON OFF

ON

GLOW PLUG

OFF

AO28002-023A


Issued 03-08


NOTES .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... ....................................................................................................................................................................................


Issued 03-08

Copyright ©

Section 4020

CNH



4020

ELECTRICAL EQUIPEMENT & ELECTRIC CIRCUIT DIAGRAMS

Copyright © 4020-2

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


Issued 03-08

Copyright © 4020-3


Issued 03-08

Copyright © 4020-4

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

OVER LOAD WARNING CONTROLLER AIR CONDITIONER CONTROLLER CONTROLLER EGR CUT COOLANT TEMPERATURE SENSOR HYDRAULIC OIL TEMPERATURE SENSOR ENGINE OIL PRESSURE SWITCH SWING PILOT PRESSURE SWITCH UPPER PILOT PRESSURE SENSOR TRAVEL PILOT PRESSURE SENSOR ENGINE RPM SENSOR OVERLOAD INDICATOR PRESSURE SWITCH BOOST PRESSURE SENSOR BOOST TEMPERATURE SENSOR HORN WORKING LIGHT (ATTACHMENT) WORKING LIGHT (CAB) CAB LIGHT SWING LAMP CIGARETTE LIGHTER AIR CONDITIONER FUSE 65A ; MAIN FUSE FOR F8 TO F26 FUSE 15A ; KEY SWITCH AND MAIN FUSE FUSE 10A ; MEMORY, CAB LIGHT, RADIO FUSE 30A ; ENGINE PRE-HEATING FUSE 10A ; SOLENOID EGR CUT FUSE 5A ; AIR CONDITIONER HEATER UNIT FUSE 15A ; AIR CONDITIONER BLOWER FUSE 5A ; AIR CONDITIONER COMPRESSOR FUSE 10A ; SOLENOID FUSE 15A ; WINDSHIELD WIPER / WASHER FUSE 10A ; HORN FUSE 15A ; LAMP (BOOM, HOUSE) FUSE 20A ; FUEL FILLER PUMP FUSE 15A ; CIGAR. LIGHTER FUSE 10A ; OVER-LOAD WARNING FUSE 10A ; DC /DC CONVERTER FUSE 10A ; BEACON FUSE 10A ; MONITOR FUSE 10A ; FUEL SUPPLY PUMP FUSE 15A ; LAMP (SWING) OPTION POWER FUSE 10A ; LEVER LOCK (GATE) FUSE 15A ; THROTTLE MOTOR FUSE 50A; SAFETY RELAY FUSE 20A; ENGINE STOP SOLENOID FUSE BOX BATTERY ALTERNATOR OVER LOAD WARNING AUDIBLE ALARM SPEAKER RIGHT SPEAKER LEFT RELAY-HORN RELAY-WORKING LIGHT RELAY-ROTARY LIGHT RELAY BATTERY RELAY SAFETY RELAY-TRAVEL MODE RELAY-SWING BRAKE RELAY-WIPER MOTOR RELAY-WASHER PUMP MOTOR RELAY-AIR CONDITIONER MAGNET CLUTCH RELAY-LOW BLOWER RELAY-MEDIUM BLOWER RELAY-HIGH BLOWER RELAY STARTER CUT RELAY EGR CUT RELAY GLOW TIMER RELAY LAMP SWING STARTER MOTOR WIPER MOTOR WASHER MOTOR MOTOR (AIR CHANGING) AIR VENT DIRECTION CONTROL MOTOR MOTOR ACT (AIR-MIX) BLOWER MOTOR THROTTLE MOTOR FUEL FEED PUMP MOTOR ELECTRIC FUEL PUMP SWITCH PANEL (LEFT-HAND) SWITCH PANEL (RIGHT-HAND)


P4. P5. P6. P10. R1. R3. R4. R5. R7. S1. S2. S6. S10. S11. S12. S13. S15. S16. S28. S33. S34. S35. S51. S52. U1. W1. X2. X8. X15. Y2. Y3. Y4. Y8. Y9. Y22. Y45.

MONITOR DISPLAY HOURMETER AIR CONDITIONER CONTROL PANEL SWITCH PANEL GLOW PLUG THROTTLE VOLUME THERMISTOR INNER TEMPERATURE FUEL SENSOR RESISTOR KEY SWITCH TRAVEL MODE SWITCH ROTARY LIGHT SWITCH WORKING LIGHT SWITCH WIPER SWITCH WASHER SWITCH OVERLOAD SWITCH HORN SWITCH IDLE SWITCH TRAVEL ALARM OPTION 2 SOLENOID VALVE SWITCH OPTION 2 SOLENOID VALVE SWITCH CRUSHER OPTION TWO FLOW SOLENOID HYDRAULIC FUNCTION CANCELLATION LEVER AIR CONDITIONING COMPRESSOR CLUTCH DC-DC (24V-12V) CONVERTER ANTENNA ROTARY LIGHT CONNECTOR RADIO CONNECTOR ACCESSORY SOCKET PILOT PRESSURE SOLENOID VALVE (BLUE SWING BRAKE SOLENOID VALVE (WHITE 2 STAGE TRAVEL SOLENOID VALVE (RED AIR CONDITIONER MAGNET CLUTCH CRUSHER OPTION TWO FLOW SOLENOID ENGINE STOP SOLENOID SOLENOID EGR CUT

Issued 03-08

Copyright © 4020-5

Electric Circuit Diagram 1

E4 H4

H5

M3 E3 X8

K20 M4

K21

E2

K4

E8

K49

P4

K18

K19

S51


Issued 03-08

Copyright © 4020-6

Electric Circuit Diagram 2 (CX75SR)

R3

0.85W 160 0.85W 161

2 0.85GrR 011 0.85WR 520 WL 821 0.85Br 510

0.85Br 513

HOUR METER

0.85BrW 514

0.85YB 412

0.85YB 412 0.85WB 318

6

YR 460 GR 462

GR 463

YL 860

ONE TOUCH IDLE

LR 461

UPPER E P.SW

YR 460

B26

P4

14 13

0.85BG 605

SWING G P.SW P.SW

B27

LR 461

1 9 MONITOR SW.PANEL

3

L 465

SWING G P.SW

BG 646

0.85Br 344

2

OIL TEMP P SW

B22

BG 645

0.85Br 344

1

B21

ENG.. OIL P-SW W BG 648

0.85VG 413 0.85WB 467

7

1.25R 347

B2

B22

0.85B 706

B51

OVER R HEAT T SW

ENGINE BG 647

0.85B 705

7

B1 1.25R 318

6

WATER TEMP SENSOR (FOR METER) R) BG 643

P4

10 0 20 0

0.85VG 413 0.25BG 640

11 12

FUEL SENSOR

R5

1 2 12 2 MONITOR SW.PANEL

0.75BW 650

0.85LgR g 504

1 17 15

6

0.85B 745

3

0.85R 0.85B

4 13

0.75W 430

RELAY BATTERY

0.75R 410

0.85W 160

LGR 500

Y 810

160

1 4 6POLE

0.85P

2

0.85G

M

THROTTLE MOTOR

0.85W

BATTERY RELAY W-LAMP ALTERNATOR

0.85L 0.85Y

5

0.85Y

500

THROTTLE VOLUME

2B 700

M10

0.85BG 605 0.85BG 720

S16 BG 610 0

YL 860

KNOB(R) R

B 747

L 865

175

S15

KNOB(L)

B81

B 712

AO30001-002


Issued 03-08

Copyright © 4020-7

Electric Circuit Diagram 2 (CX80)

R3

M10

P4 R5

B1

B51 B21

B2

P4

B22 B22 B27 B26 B22 B22 S34

S16 S33

B81


S15

Issued 03-08

Copyright © 4020-8

Electric Circuit Diagram: Air Conditioner 1

AIR CONDITIONER UNIT

M

1

BLOWER MOTOR

2

RESISTOR

3 2 1 4POLE 4

M

5 4 6 3 2

MODE BOX

1.25WR 200

0.85LB 540

0.85LY 541

0.85LW 542

O 549

YR 556

BG 557

WR 554

RY 555

LgB g 553

O 551

O 549

10

6

2

M

LY 563

1

13

12

WG 547

14

GR 548

27

0.

2

RY 555

CONTROLLER AMP.

AIR CON.BACK UP AIR CON.POWER

16 0.85B 720

5 0.85VR 195

17

0.

AIR CON. CONTROL AMP. CN-AC1 30POLE 3 9 11

3

CN-WATER VALVE

1

RECIRCULATE/FRESH

LW 543

24

4

M5

7

19

M

GY 581

1

WL 559

A9 YW 558

15 WR 554

2

BG 557

BG 562

CN-WATER VALVE

GY 581

WATER VALVE

R 151

K24

1

1.25W 981

150 200 195 205

OR R

R 150

K22

WB 564 WB 564

LR 546

K25

COMPRESSOR

0.8

YR 556

Issued 03-08


K23

S52

0.

LgB g 553 G 560

OL 545

Y8

0 550

M6

M8 R7 R4

AO30001-003

2

Copyright ©

4020-9

Electric Circuit Diagram: Air Conditioner 2

4

13

CONTROL AMP

14

18

2

16

7

8

5

3

6

17

LW 576 GW 570 RY 567 RW 569 OR 572 LgR g 571 BrR 575 LR 566 GR 577 BW 573 WR 568 WG 574

8

7

6

P6 15

16

3

18

CONTROL PANEL

13

4

5

14

1

2

WL 822

W-LAMP

820 195

Issued 03-08


2B 700 2B 600

2B 700 2B 600

VR 196

A9

AO30001-004


NOTES .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... ....................................................................................................................................................................................


Issued 03-08


WIRING DIAGRAM Electrical Components and Wiring For Upper (frame) CN181 (PRESS. SW;TRAVEL:2PINS) WITHOUT COLOR TAPE

DESCRIPTION

CN146 (BOOM LAMP HARNESS;2PINS) CND12 (RECIEVER DRIER;2PINS)

MARKING POSITION ; FIT THE HARNESS'S WHITE TAPE

CN180 (PRESS. SW;UPPER:2PINS) 1 WITH RED TAPE

QTY

PRESS. SWITCH

1

2

WIRE HARNESS

2

1

PRESS. SWITCH

3

2

HORN

4

1

THERMO SWITCH

5

1

WIRING HARNESS

6

1

TRAVEL ALARM

7

1

KHR20160 CABLE;BATTERY

C~ TANK;FUEL

SYM

CN135 (FUEL LEVEL SENSOR:3PINS)

TANK;SUMP

A D A~

MARKING POSITION

F

D~ DETAIL-E

B

CN.147 (WASHER MOTOR;2PINS)

C L

AIR COMPRESSER THROTTLE MOTOR

SEE DETAIL-E

G

CONNECT TO HARNESS;WIRE

HOSE COOLER

H K 2

J J~ MARKING POSITION ; FIT THE HARNESS'S WHITE TAPE

B~

4

I PRESSURE SWITCH (UPPER) 2PINS

3

L~

CN188 (OIL TEMP SW;2PINS) (TRAVEL ALARM;TERMINAL)

5

F~

6 CN127 (SHUT OFF S.V;2PINS) WITH BLUE TAPE

CN128 (SWING BREAK S.V;2PINS) WITH PINK TAPE

CN.G1(GROUND) CN.G3 (ALTERNATOR GROUND) CN.G4 (ENGINE STOP GROUND)

CN136 (FUEL PUMP:2PINS)

G~

CN129 (TRAVEL S.V;2PINS) WITH RED TAPE

MARKING POSITION ; FIT THE HARNESS'S WHITE TAPE

7

I~

H~

KHR20160 CABLE;BATTERY

K~ KAR10930-D00


Issued 03-08


Electrical Components and Wiring for Cab

1

8

1

CONNECTOR:OVER LORD WARNING(8PIN)

LANP SWING X10

4

DESCRIPTION

STARTER CUT(WHITE TAPE)

HORN(WHITE TAPE) SWING BRAKE

7

A

CONNECTOR:DC-DC COMVERTER (7PIN)

6 B

EGR CUT

9

BEACON(WHITE TAPE)

PIN TERMINAL:PRESSURE CHECK

BLOWER L BLOWER M CONNECTOR:GROW TIMER 2

BLOWER H

CONNECTOR:GROW TIMER 1

7

BOX;FUSE (ATTACHMENT FOR CAB MAIN HARNESS)

COMPRESSOR

FRAME MAIN HARNESS

LAMP(WHITE TAPE) TRAVEL MODE(WHITE TAPE) WASHER(WHITE TAPE) WIPER(WHITE TAPE)

B

DETAIL OF ASSEMBLING RELAY

SYM

QTY

LOUD SPEAKER

1

2

RADIO SET AM/FM ST(12/24V) NA

2

1

ANTENNA CODE

3

1

DC-DC CONVERTER

4

1

WIRE HARNESS

5

1

BUZZER (24V)

6

1

SOCKET (DC12V)

7

1

CONTROLLER

8

1

CHANGE OVER RELAY

9

10

ROCKER SWITCH

10

1

WORKING LIGHT

11

1

MONITORÅ@24V

12

1

STARTER SWITCH ASSY

13

1

ROCKER SWITCH

14

1

ROCKER SWITCH

15

1

CONNECTOR:CONT EGR CUT(13PIN)

5

CONNECTOR;THERMISTOR

MARKING POSITION CONNECTOR:OPTION POWER (FIT HARNESS WHITE TAPE) (4PIN) (FIX WITH RED TAPE) CONNECTOR:SUB HARNESS

5

CONNECTOR;BLOWER MOTOR

CONNECTOR;AIRCON CONTROLER CONNECTOR;RESISTOR

(2PIN) (FIX WITH RED TAPE) CONNECTOR;MODE BOX

DETAIL OF ELEC. BRACKET

2

12

13

12V OUTPUT (FIX WITH RED TAPE)

3

DETAIL OF ASSEMBLING RADIO 11 14 BACKSIDE OF COVER;TOP (RIGHT)

PANEL;CONTROL

CONNECTOR;WATER VALVE

CONNECTOR;FRESH AIR

DETAIL OF AIRCON HARNESS 13

12 8 BACKSIDE OF COVER;TOP (LEFT) 10

15

A

HARNESS;BEACON SW(WHITE TAPE) HARNESS;OVER LOAD WARNING SW(BLUE TAPE) CONNECT TO CAB HARNESS

CONSOLE RIGHT

DETAIL OF ASSEMBLING SWITCH

FRAME MAIN HARNESS SWITCH;LIMIT

3 CONNECT TO ANTENNA CORD OF CAB

CONSOLE LEFT KAR10750-E00


Issued 03-08


Electrical Components and Wiring for Upper Frame (engine) DESCRIPTION

CN193 TERMINAL(FEMALE) CN192 (EGR CUT;2PINS) (WATER TEMP. SENSOR 1)

CN189 RING TERMINAL M4 (GLOW)

CN196 RING TERMINAL M4 (OIL PRESS SWITCH)

THERMO SENSOR

SYM

QTY

1

1

HEATER HOSE

DETAIL-A

CN194 PIN TERMINAL(FEMALE) (TACHO SENSOR) SEE DETAIL-A

CN195 PIN TERMINAL(MALE) (TACHO SENSOR) CN.D13 (AIR COMPRESSOR)1PIN CODE COLOR:WHITE

B

AIR COMPRESSOR

B~ BE CAREFUL OF THE DIRECTION OF BATTERY CABLE STARTER MOTOR (ATTACHMENT FOR ENGINE)

CN190 (ENGINE STOP;3PINS) CN109 TERMINAL(FEMALE) (STARTER MOTOR S)

DETAIL OF STARTER MOTOR KAR10690 (HARNESS;WIRE)

CN.179 RING TERMINAL M4 (WATER TEMP. SENSOR 2) CODE COLOR:RED

CN187 (BOOST PRESS SENSOR;3PINS)

CN186 RING TERMINAL M4 (OVER HEAT SWITCH) CODE COLOR:RED

SAFTY RELAY(ATTACHMENT FOR ENGINE)

C

CN.111 RING TERMINAL M6 (ALTERNATOR:B) CODE COLOR:RED

CN110 (ALTERNATOR L,R;2PINS)

1 ENGINE EARTH (ATTACHMENT FOR ENGINE)

CN.112 RING TERMINAL M6 (ALTERNATOR:E) CODE COLOR:BLACK

~

CN106 (SAFTY RELAY:S.R.E)3PIN

DETAIL-D

CN108 (SAFTY RELAY:C)1PIN

E

C~ E~

KHR20160 CABLE;BATTRY CN107 (SAFTY RELAY:C)1PIN

KHR20160 CABLE;BATTRY

SEE DETAIL-D KAR10940-D00


Issued 03-08


Electrical Components and Wiring for Upper Frame (battery)

CN104 RING TERMINAL M4(BATTERY RELAY COIL) CODE COLOR:WHITE BASE,RED STRIPE CN103 RING TERMINAL M4(BATTERY RELAY COIL) CODE COLOR:LIGHT GREEN BASE,RED STRIPE

6

1 TANK;SUMP

5

DESCRIPTION

SYM

QTY

BATTERY CABLE

1

1

BATTERY HOLDER

2

1

BATTERY 95D31R

3

2

BATTERY CABLE

4

1

BATTERY CABLE

5

1

BATTERY CABLE

6

1

BATTERY RELAY

7

1

FUSE

8

1

FUSE 50A

9

1

4

2

7

M8(ATTACHMENT FOR BATTERY) TIGHTENING TORQUE 6.0 + or - 0.5 Nm(4 POINTS) 3

CNG1 (GROUND) CODE COLOR:BLACK

6

CN105 (BATTERY RELAY GND)1PIN

DETAIL OF BATTERY (DETACH PLATE;RUBBER) 6 M10(ATTACHMENT FOR BATTERY) TIGHTENING TORQUE 11.8 + or - 1.2 Nm(4 POINTS)

5

CN101 (BATTERY RELAY 1GN) CODE COLOR:RED

5

CN100 (BATTERY RELAY B+) WITH WHITE TAPE

DETAIL OF BATTERY RELAY

HOUSE;FRAME

A

CNF3 (FUSE:KEY 15A)2PINS WITHOUT TAPE

CNF4 (FUSE:ENGINE STOP 20A)2PINS WITH RED TAPE

8

9

CNF7 (FUSIBLE LINK 65A)2PINS CODE COLOR:RED

CNF2 (FUSIBLE LINK 50A)2PINS CODE COLOR:RED WHITE BASE,RED STRIP

KAR10690 (HARNESS;WIRE)

A~ DETAIL OF BATTERY (INSIDE)

DETAIL OF FUSE KAR10860-D00


Issued 03-08


Heater HEATER(ENG.OUT) THE HOSE LENGTH FROM THIS CLAMP TO THE HEATER UNIT. HEATER INLET:780 mm HEATER OUTLET:660 mm

WHITE MARKING

HEATER(ENG.RETURN)

DETAIL-A

IN CONNECT HEATER UNIT

OUT CONNECT HEATER UNIT

HEATER(ENG.RETURN)

HEATER(ENG.OUT) THE HOSE LENGTH FROM THIS CLAMP TO THE NIPPLE. HEATER OUTLET:700 mm HEATER INLET:550 mm

DETAIL-A

KAR10850-D00


Issued 03-08


Air Conditioner (inside Frame)

THE HOSE LENGTH FROM THIS CLAMP TO THE COMPRESSOR. DISCHARGE:290 mm

OUT IN

HEATER(ENG.OUT) HEATER(ENG.RETURN)

WHITE MARING. THE HOSE LENGTH FROM THIS CLAMP TO THE UNIT;AIR CONDITIONER. LIQUID 2:800 mm SUCTION:700 mm HEATER INLET:780 mm HEATER OUTLET:660 mm

SEE DETAIL-B

DETAIL-A DETAIL RECEIVER;DRIER ASSEMBLING

BE CAREFUL OF DIRECTION.

HEATER(ENG.RETURN) IN CONNECT AIR CON UNIT

OUT CONNECT AIR CON UNIT

LIQUID CONNECT AIR CON UNIT

DETAIL-B

HEATER(ENG.OUT)

SUCTION CONNECT AIR CON UNIT

SUCTION

SEE DETAIL-A

DETAIL PULLY ASSEMBLING

THE HOSE LENGTH FROM THIS CLAMP TO THE NIPPLE AND COMPRESSOR. HEATER OUTLET:700 mm HEATER INLET:550 mm SUCTION:520 mm

.

THE HOSE LENGTH FROM THIS CLAMP TO THE RECEIVER;DRIER AND CONDENSER LIQUID 2:930 mm DISCHARGE:830 mm

DISCHARGE

KAR10830-E00


Issued 03-08


Air conditioner (inside cab)

SYM

QTY

CHANGE OVER RELAY

DESCRIPTION

1

3

CONTROL PANEL

2

1

WHITE MARKING CONNECT TO DCCT;SPL COOLER INLET COOLER OUTLET HEATER OUT

HARNESS;WIRE CONTROLLER MODE BOX

BLOWER MOTOR

THERMISTOR

X3

1

BLOWER H BLOWER M BLOWER L COMPRESSOR

RESISTOR

1

ONLY AIR CONDITIONER

10

DETAIL OF RELAY ASSEMBLING 10

2

A

COVER;FRONT

BOX;CONSOLE(L)

KHR3949Z-D07


Issued 03-08


ELECTRICAL CONNECTOR WIRING DIAGRAM Main Frame Harness (CX75SR)

CMF7M

KAR10690-E00


Issued 03-08


Main Frame Harness (CX80)

CMF7M (FUSIBLE LIMK (FUSE BOX))


Issued 03-08


Cab Main Harness (inside cab)

CN28F (AIRCON CONTROLER AMP 2)

CN29F

KAR10710-E00


Issued 03-08

5001

Copyright ©

Section 5001 REMOVAL AND INSTALLATION OF THE TRACKS

CNH

Lep SM75SR5001-0EN


Copyright © 5001-2

TABLE OF CONTENTS TRACK SHOE.......................................................................................................................................................... 3 Removal ............................................................................................................................................................ 4 Installation ......................................................................................................................................................... 5 TRACK LINK CHANGING PROCEDURE ...................................................................................................................... 6

Lep SM75SR5001-0EN

Issued 08-2008

Copyright © 5001-3

TRACK SHOE 1

2

10

8

5 11 9 11 6

3

13 7

12 13 4

16

14

15

AQ10002-001

1. 2. 3. 4. 5. 6. 7. 8.

Grouser shoe Track link assembly Track link (right) Track link (left) Master link (right) Master link (left) Track bushing Track pin

Lep ASM-17-10-002EN

9. 10. 11. 12. 13. 14. 15. 16.

Master bushing Master pin Collar Locking pin Seal Shoe plate Shoe bolt Shoe nut

Issued 08-2008

Copyright © 5001-4 1 Removal [1] Position the master pin (1) of the track shoe as shown in the drawing on the left. Place track shoe support blocks as shown in the drawing.

1

AQ10002-002

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

AQ10002-003

[3] Separate the track shoe. 1) Remove the locking pin (2). 2) Pull out the master pin using a jig. 3) Remove the track shoe supporting blocks.

2

AQ10002-004

[4] Lift one side of the lower frame about 20 cm and hold it there. WARNING: Place protection blocks under the lower frame and secure them. Move the travel unit as shown in the drawing to the left to remove the track shoe.

AQ10002-006

Lep ASM-17-10-002EN

Issued 08-2008

Copyright © 5001-5 2 Installation [1] Lift the track shoe and align it to the drive sprocket.

AQ10002-007

[2] Feed the track shoe toward the take-up roller by moving the travel unit slowly as shown in the drawing to the left. NOTE: Be careful. Sudden and quick movements may cause the track shoe to jump and run off. (During work, lift the roller shoe using the steel bar when crossing over the upper roller). [3] Remove protection blocks and lower the lower frame.

AQ10002-008

[4] Wind the end of the track shoe onto the take-up roller of the track shoe. [5] Connect the track shoe. 1) Place the track shoe supporting blocks. 2) Insert the master pin using a jig. 3) Insert a locking pin.

AQ10002-009

[6] Adjust the track shoe to the specified tension. 1) Fasten the check valve to the original position. 2) Fill the grease cylinder with grease, while observing the track shoe tension. NOTE: For the track shoe tension adjustment, refer to Inspection and Maintenance in the Instruction Manual.

AQ10002-010

Lep ASM-17-10-002EN

Issued 08-2008

Copyright © 5001-6

1 Track link changing procedure 1) Remove the track shoe. 2) Remove bolts, nuts and shoe plates for three sections, including the sections on both sides of the damaged link section. 3) Pull the track pin using a jig. 4) Remove the damaged link. 5) Align a new track link. 6) Press fit the track pin using a jig. 7) Align the shoe plate and tighten the bolts to the specified torque. 8) Install the track shoe. AQ10002-011

Lep ASM-17-10-002EN

Issued 08-2008

Copyright ©

5003

Section 5003 UPPER AND LOWER ROLLERS

CNH

Lep SM75SR5003-0EN


Copyright © 5003-2

TABLE OF CONTENTS TRACK SHOE.......................................................................................................................................................... 3 UPPER ROLLER ..................................................................................................................................................... 3 Removal ............................................................................................................................................................ 4 Installation ......................................................................................................................................................... 4 Tools and jigs .................................................................................................................................................... 5 Disassembly instructions................................................................................................................................... 7 Assembly instructions ....................................................................................................................................... 9 Assembly drawings ......................................................................................................................................... 13 LOWER ROLLER .................................................................................................................................................. 14 Removal .......................................................................................................................................................... 15 Installation ....................................................................................................................................................... 15 Component diagram........................................................................................................................................ 16 Tools and jigs .................................................................................................................................................. 16 Disassembly instructions................................................................................................................................. 18 Assembly instructions ..................................................................................................................................... 21 Assembly drawings ......................................................................................................................................... 24

Lep SM75SR5003-0EN

Issued 08-2008

Copyright © 5003-3

TRACK SHOE 1 Upper roller

AQ10002-023

1. 2. 3. 4.

Upper roller Bolt Loctite 262 Shim

Lep ASM-17-10-002EN

Issued 08-2008

Copyright © 5003-4 1 Removal [1] Loosen track shoe. See “Track shoe, removal”. [2] Place the hydraulic jack (A) as shown in the drawing to the left.

AQ10002-024

A

[3] Using the hydraulic jack (A), lift the track shoe high enough that the upper roller can be removed.

A

[4] Place blocks between the track shoe and side frame and secure them. [5] Loosen the upper roller mounting bolt (2) slightly (so that the bolt head comes off 2 to 4 mm). [6] Hit the upper roller gently with a copper hammer and detach it from the side frame. [7] Attach lifting tools on the upper roller. [8] Remove the upper roller by removing mounting bolts (2) completely while lifting the upper roller using the lifting tools.

AQ10002-025

NOTE: Be careful to keep fingers and hands clear. 2 Installation [1] Apply Loctite No. 262 to the upper roller mounting bolts (2). [2] Finger tighten all upper roller mounting bolts (2) while lifting the upper roller. NOTE: Adjust the position of the upper roller if necessary, using shims (4) so that the track links are evenly supported. [3] Tighten the upper roller mounting bolts (2) to the specified torque. [4] Remove the blocks and jack. [5] Fill grease into the grease cylinder and give the track shoe the specified tension. (See Track shoe, installation).

Lep ASM-17-10-002EN

Issued 08-2008

Copyright © 5003-5 3 Component diagram 1.

Cover

2.

O-ring

3.

Plug

4.

Snap ring

5.

Ball bearing

6.

Roller

7.

Shaft

8.

Oil seal

9.

Cover

10. Bracket

AQ14002-001

4 Tools and jigs 1.

Tools

Hammer

AQ13002-002

Hexagon bar wrench

AQ13002-003

Lep ASM-17-14-002EN

Issued 08-2008

Copyright © 5003-6 2.

Jigs

Install jig.

AQ13002-004

Pulling jig

AQ13002-005

Lep ASM-17-14-002EN

Issued 08-2008

Copyright © 5003-7 5 Disassembly instructions [1] Preparation Prior to disassembly, take full preparatory measures. 1) Workbench with vises Prepare a suitable workbench large enough to arrange and keep parts and perform the work. 2) Tools and Jigs For tools and jigs, refer to the previous section. [2] General cautions 1) Handle precision parts carefully during the operation; do not drop or hit them on other parts during the operation. 2) Do not attempt to finish the operation quickly; do not forcedly pry or hit the parts. Perform the operation carefully and patiently in order to prevent parts deformation, oil leakage and lower efficiency. 3) As disassembled parts tend to get rusted or collect dust and dirt, dust proof and rust prevention treatment should be applied immediately after disassembling the parts. [3] Disassembling procedure 1) 1) Clean the upper roller with kerosene. 2) Remove the plug (3) from the cover to drain the oil.

AQ14002-006

2) 1) Remove the cover (1) from the upper roller (6) using a press and a pulling jig. 2) Remove O-ring (2) from the cover (1).

AQ14002-003

Lep ASM-17-14-002EN

Issued 08-2008

Copyright © 5003-8 3) Remove snapring (4) from shaft (7).

AQ14002-004

4) Pull out the roller (6) from the shaft (7).

AQ14002-005

5) Remove the cover (9) and oil seal (8) from roller using a press and a pulling jig.

AQ14002-006

Lep ASM-17-14-002EN

Issued 08-2008

Copyright © 5003-9 6) Remove ball bearings (5) from roller (6) using a press and a pulling jig. Do not disassemble ball bearings (5) unless they are unusable due to wear.

AQ14002-007

7) Cleaning parts 1) Place parts in the preparatory cleaning container containing cleaning oil. NOTE: Wash off deposited substances which may cause scratches. NOTE: Leave the parts submerged in the kerosene until the dirt and grease come off and float up 2) Put the parts in the finish cleaning container containing cleaning oil and wash them by slowly moving them. 3) Wipe off remaining cleaning oil with clean cloth. NOTE: Place the parts somewhere free of dust and moisture, and dry them using compressed air. After drying, apply engine oil to the parts. 6 Assembly instructions [1] Prior to assembly • Clean all the parts. • Polish scratches, flashes or burrs using oil stons. • Change sealing parts such as O-rings with new ones. [2] Assembling procedure 1) Press fit the shaft (7) into the bracket (10). Press fitting should be securely conducted through the side of the plug hole. NOTE: In an ordinary case, do not disassembly the bracket from the shaft. Reassembly will be a very difficult task.

AQ14002-008

Lep ASM-17-14-002EN

Issued 08-2008

Copyright © 5003-10 2) Install the ball bearings (5) on roller (6) using a jig and a hammer. NOTE: Use new ball bearings (5).

AQ14002-009

3) 1) Install the oil seal (8) and cover (9) to the roller (6). 2) Apply oil to the surface (lip section) of the floating seal. NOTE: Do not reuse oil seal (8).

AQ14002-010

4) 1) Apply grease to the shaft (7) surface. 2) Install roller (6) into shaft (7).

AQ14002-011

Lep ASM-17-14-002EN

Issued 08-2008

Copyright © 5003-11 5) Install snap ring (4) on shaft (7). NOTE: Do not reuse O-ring (4).

AQ14002-012

6) 1) Apply grease to O-ring (2) and install on cover (1). 2) Press fit the cover (1) with the O-ring attached on roller (6), using a press and a jig. NOTE: Use a new O-ring.

AQ14002-013

7) Check for leakage in the assembly using compressed air. Compressed air pressure: 0.2 MPa.

AQ14002-014

Lep ASM-17-14-002EN

Issued 08-2008

Copyright © 5003-12 8) Fill oil through the plug hole.

AQ14002-015

9) Install the plug (3). NOTE: Clean the assembly and dry it using compressed air.

AQ14002-016

Now the assembly has been completed.

Lep ASM-17-14-002EN

Issued 08-2008

Copyright © 5003-13 7 Assembly drawings

-##<$

1. 2. 3. 4. 5.

Cover (1) O-ring 1B-G65 (1) Plug 1/8 (1) Snap ring (1) Ball bearing (2)

Lep ASM-17-14-002EN

6. 7. 8. 9. 10.

Roller (1) Shaft (1) Oil seal (1) Cover (1) Bracket (1)

Issued 08-2008


2 Lower roller

AQ10002-026

1. Lower roller 2. Bolt 3. Loctite 262

ASM-17-10-002

Issued 08-2008

Copyright © 5003-15 1 Removal [1] Loosen track shoe. See “Track shoe, removal”. [2] Remove the lower roller mounting bolts (2). [3] Lift one side of the lower frame about 200 mm and hold it there. (Lift it high enough that the lower roller can be removed from the track shoe). [4] Place protection blocks under the lower frame and secure them.

AQ10002-027

[5] Remove the lower roller (1) from the track shoe.

AQ10002-028

2 Installation [1] Place the lower roller on the track links with its fitting surface up. [2] Remove the protection blocks. [3] Lower the frame slowly and gradually to where the bolts can be installed. NOTE: Be careful to keep fingers and hands clear. (Keep the frame raised about 5 to 10 mm, instead of lowering it completely.) [4] Align the lower roller to the frame fitting position. [5] Apply Loctite No. 262 to the lower roller mounting bolts (2). [6] Tighten the lower roller mounting bolts (2) to the specified torque. [7] Fill the grease cylinder with grease to give the track motor cover shoe the specified tension. (See Track shoe, installation).

ASM-17-10-002

Issued 08-2008

Copyright © 5003-16 3 Component diagram 1.

Collar (without plug)

2.

Roller

3.

Shaft

4.

Bushing

5.

Floating seal

6.

O-ring

7.

Wire clip

8.

Collar (with plug)

9.

Plug

AQ15002-001

4 Tools and jigs 1.

Tools

Hammer

AQ13002-002

Hexagon bar wrench

AQ13002-003

ASM-17-15-002

Issued 08-2008


Jigs

Install jig

AQ13002-004

Pulling jig

AQ13002-005

ASM-17-15-002

Issued 08-2008

Copyright © 5003-18 5 Disassembly instructions [1] Preparation Prior to disassembly, take full preparatory measures. 1) Workbench with vises Prepare a suitable workbench large enough to arrange and keep parts and perform the work. 2) Tools and Jigs For tools and jigs, refer to the previous section. [2] General cautions 1) Handle precision parts carefully during the operation; do not drop or hit them on other parts during the operation. Do not attempt to finish the operation quickly; do not forcedly pry or hit the parts. 2) Perform the operation carefully and patiently in order to prevent parts deformation, oil leakage and lower efficiency. 3) As disassembled parts tend to get rusted or collect dust and dirt, dust proof and rust prevention treatment should be applied immediately after disassembling the parts. [3] Disassembling procedure 1) 1) Clean the lower roller with kerosene. 2) Remove the plug (9) from the collar (8) to drain the oil.

AQ15002-002

2) 1) Remove the wire clips (7) from the shaft (3). 2) Remove the collars (1), (8) from the shaft (3).

AQ15002-003

ASM-17-15-002

Issued 08-2008

Copyright © 5003-19 3) Remove the floating seals (5) from the collars (1), (8) using pulling jig.

AQ15002-004

4) 1) Remove the O-rings (6) from the shaft (3). 2) Draw out the shaft (3) from the roller (2).

AQ1002-005

5) Remove the floating seals (5) from the roller (2).

AQ15002-006

ASM-17-15-002

Issued 08-2008

Copyright © 5003-20 6) Remove the bushings (4) from the roller (2) using pulling jig and press.

AQ15002-007

7) Cleaning parts 1) Place parts in the preparatory cleaning container containing kerosene. NOTE: Wash off deposited substances which may cause scratches. NOTE: Leave the parts submerged in the kerosene until the dirt and grease come off and float up 2) Put the parts in the finish cleaning container containing kerosene and clean them by slowly moving them. 3) Wipe off kerosenel with clean cloth. NOTE: Place the parts somewhere free of dust and moisture, and dry them using compressed air. After drying, apply engine oil to the parts.

ASM-17-15-002

Issued 08-2008

Copyright © 5003-21 6 Assembly instructions [1] Prior to assembly • Clean all the parts. • Polish scratches, flashes or burrs using oil stone. • Change sealing parts such as O-rings with new ones. [2] Assembling procedure 1) Install the bushings (4) to the roller (2) using jig and hammer. NOTE: Pay full attention when inserting the bushings by hammering. Do not reuse bushings (4).

AQ15002-008

AQ15002-009

2) Install the floating seals (5) to the roller (2). NOTE: Do not reuse floating seals (5).

AQ15002-006

ASM-17-15-002

Issued 08-2008

Copyright © 5003-22 3) 1) Apply grease to the surface of the shaft (3). 2) Install the shaft (3) to the roller (2). 3) Install the greased O-rings (6) to the shaft (3). NOTE: Do not reuse O-ring (6).

AQ15002-005

4) Install the floating seals (5) to the collars (1), (8). NOTE: Do not reuse floating seals (5).

AQ15002-004

5) Apply oil to the surface (lip section) of the floating seal.

AQ15002-010

ASM-17-15-002

Issued 08-2008

Copyright © 5003-23 6) Press fit the collars (1), (8) to the shaft (3) and install the wire clips (7). (Temporary fastening) NOTE: Do not reuse wire clips (7).

AQ15002-003

7) Check for leakage in the assembly using compressed air. Compressed air pressure: 0.2 MPa.

AQ15002-011

8) Intall the wire clips (7) using a hammer. NOTE: Do not reuse wire clip (7).

AQ15002-012

9) 1) Fill oil through the plug hole. 2) Install the plug (9). NOTE: Clean the assembly and dry it using compressed air.

AQ15002-002


ASM-17-15-002

Issued 08-2008


-##<%

1. 2. 3. 4. 5.

Collar (without plug) (1) Track roller (1) Roller shaft (1) Bushing (2) Floating seal (2)

ASM-17-15-002

6. 7. 8. 9.

O-ring 1B-G35 (2) Wire clip (2) Collar (with plug) (1) Plug 1/8 (1)

Issued 08-2008

Copyright ©

Section 5005

5005

TAKE-UP ROLLER AND TENSION SHOCK ABSORBER

CNH

Lep SM75SR5005-0EN


Copyright © 5005-2

TABLE OF CONTENTS TAKE-UP ROLLER AND TENSION SHOCK ABSORBER .................................................................................... 3 Removal ............................................................................................................................................................ 4 Installation ......................................................................................................................................................... 5 GREASE CYLINDER ................................................................................................................................................ 6 Component diagram.......................................................................................................................................... 6 Tools and jigs .................................................................................................................................................... 6 Disassembly instructions................................................................................................................................... 7 Assembly instructions ....................................................................................................................................... 8 Assembly drawings ......................................................................................................................................... 10 TAKE-UP ROLLER ................................................................................................................................................ 11 Component diagram........................................................................................................................................ 11 Tools and jigs .................................................................................................................................................. 11 Disassembling instructions.............................................................................................................................. 13 Assembling instructions .................................................................................................................................. 16 Assembly drawings ......................................................................................................................................... 20

Lep SM75SR5005-0EN

Issued 08-2008

Copyright © 5005-3

TAKE-UP ROLLER AND TENSION SHOCK ABSORBER

#3

1. 2. 3. 4. 5. 6. 7. 8. 9.

Yoke Bolt Threaded rod Castle nut Spring pin Spring Grease cylinder assembly O-ring Backup ring

ASM-17-10-002

10. 11. 12. 13. 14. 15. 16. 17.

Check valve Dust seal Piston rod Grease cylinder Bracket High strength bolt Spring washer Take-up roller

Issued 08-2008

Copyright © 5005-4 1 Removal [1] Remove track shoe. See “Track shoe, removal”. [2] Pull out the recoil spring assembly from the side frame using a steel bar. [3] Attach a lifting tool to the recoil spring assembly..

AQ10002-019

[4] Lift the recoil spring assembly out from the side frame using the lifting tool. [5] Place the recoil spring assembly on blocks. [6] Remove the take-up roller mounting bolts (2) to separate the take-up roller and coil spring. [7] Prepare hydraulic jack and jigs for recoil spring disassembling and reassembling. [8] Set recoil spring in jig as shown in the drawing to the left. [9] Raise the hydraulic jack to compress the spring. [10]Pull out the spring pin (5) and remove the castle nut (4).

AQ10002-020

[11]Lower the hydraulic jack to restore the spring to its original position. [12]Take the recoil spring components out from the jig in the following order: yoke (1), spring (6) and grease cylinder (7).

ASM-17-10-002

Issued 08-2008

Copyright © 5005-5 2 Installation [1] Set the recoil spring components in the recoil spring jig in the following order: grease cylinder (7) spring (6) and yoke (1). [2] Raise the hydraulic jack to compress the spring. Mounting length of spring: 402 mm [3] Attach the castle nut (4) and lock it with spring pin (5).

AQ10002-021

[4] Lower the hydraulic jack to restore the spring to the original position. [5] Remove the recoil spring from the jig. [6] Apply Loctite No. 262 to the take-up roller mounting bolts (2). [7] Tighten the take-up roller mounting bolts (2) to the specified torque to reassemble the take-up roller and recoil spring. [8] Attach lifting tool to recoil spring assembly. [9] Place recoil spring assembly on side frame using a lifting tool.

AQ10002-022

[10]Set the recoil spring assembly in the side frame using a steel bar. [11]Install the track shoe. (See Track shoe, installation.) WARNING: A jig should be used for disassembly and reassembly because the coil spring is compressed.

ASM-17-10-002

Issued 08-2008

Copyright © 5005-6

1 Grease cylinder 1 Component diagram

KAA1160Z-C01

1. 2. 3. 4. 5.

Dust seal Backup ring O-ring Piston rod Grease cylinder

6. 7. 8. 9.

High strength bolt Spring washer Bracket Check valve

2 Tools and jigs 1.

Tools

Hammer

AQ16002-002

Spanner

AQ16002-003

Socket

AQ16002-004

Ratchet handle

AQ16002-005

2.

Jigs

Install jig

AQ16002-006

Pulling jig

AQ16002-007

ASM-17-16-002

Issued 08-2008

Copyright © 5005-7 3 Disassembly instructions [12]Preparation Prior to disassembly, take full preparatory measures. 1) Workbench with vises Prepare a suitable workbench large enough to arrange and keep parts and perform the work. 2) Tools and Jigs For tools and jigs, refer to the previous section. [13]General cautions 1) Handle precision parts carefully during the operation; do not drop or hit them on other parts during the operation. 2) Do not attempt to finish the operation quickly; do not forcedly pry or hit the parts. Perform the operation carefully and patiently in order to prevent parts deformation, oil leakage and lower efficiency. 3) As disassembled parts tend to get rusted or collect dust and dirt, dust proof and rust prevention treatment should be applied immediately after disassembling the parts. [14]Disassembling procedure 1) 1) Clean grease cylinder with kerosene. 2) Remove bolts (6), washers (7) and then remove the bracket (8). 3) Remove check valve (9) from grease cylinder (5).

AQ16002-008

2) Draw out piston rod (4) from grease cylinder (5).

AQ16002-009

ASM-17-16-002

Issued 08-2008

Copyright © 5005-8 3) Remove dust seal (1) from grease cylinder (5) using pulling jig.

AQ16002-010

4) Remove back-up ring (2) and O-ring (3) from grease cylinder (5).

AQ16002-011

4 Assembly instructions [1] Prior to assembly • Clean all the parts. • Polish scratches, flashes or burrs using oil stone. • Change sealing parts such as O-rings with new ones. [2] Assembling instructions 1) 1) Install grease-applied O-ring (3) to grease cylinder (5). 2) Install back-up ring (2). NOTE: Do not reuse back-up ring (2) and O-ring (3).

AQ16002-011

ASM-17-16-002

Issued 08-2008

Copyright © 5005-9 2) 1) Install dust seal (1) to grease cylinder (5) using a jig and hammer. 2) Apply grease on lip section of dust seal. NOTE: Do not reuse dust seal (1).

AQ16002-010

AQ16002-013

3) 1) Apply grease to the surface of piston rod (4). 2) Insert piston rod (4) into grease cylinder (5).

AQ16002-012

4) 1) Install check valve (9) to grease cylinder (5) by applying specified tightening torque. 2) Install bracket (8), and then fasten it with bolts (6) and washers (7). NOTE: Do not reuse floating seals (5).

AQ16002-008

ASM-17-16-002

Issued 08-2008


KAA1219Z-B01

1. 2. 3. 4. 5.

Dust seal (1) Back-up ring T-P60 (1) O-ring 1B-P60 (1) Piston rod (1) Grease cylinder (1)

ASM-17-16-002

6. 7. 8. 9.

High strength bolt M8 x 16 (2) Spring washer 8 (2) Bracket (1) Check valve (1)

Issued 08-2008


2 Take-up roller 1 Component diagram 1.

Take-up roller

2.

Bushing

3.

Floating seal

4.

O-ring

5.

Shaft

6.

Spring pin

7.

Hub (with plug)

8.

Plug

9.

Hub (without plug)

AQ13002-001

2 Tools and jigs 1.

Tools

Hammer

AQ13002-002

Hexagon bar wrench

AQ13002-003

ASM-17-13-002

Issued 08-2008


Jigs

Install jig

AQ13002-004

Pulling jig

AQ13002-005

ASM-17-13-002

Issued 08-2008

Copyright © 5005-13 3 Disassembling instructions [1] Preparation Prior to disassembly, take full preparatory measures. 1) Workbench with vises Prepare a suitable workbench large enough to arrange and keep parts and perform the work. 2) Tools and Jigs For tools and jigs, refer to the previous section. [2] General cautions 1) Handle precision parts carefully during the operation; do not drop or hit them on other parts during the operation. Do not attempt to finish the operation quickly; do not forcedly pry or hit the parts. 2) Perform the operation carefully and patiently in order to prevent parts deformation, oil leakage and lower efficiency. 3) As disassembled parts tend to get rusted or collect dust and dirt, dust proof and rust prevention treatment should be applied immediately after disassembling the parts. [3] Disassembling procedure 1) 1) Clean the take-up roller with kerosene. 2) Remove the plug (8) from the hub (7) to drain the oil.

AQ13002-006

2) 1) Remove the spring pin (6) from the shaft (5) (or hub (7). The removal is to be performed on one side only. 2) Remove the hub (7) from the shaft (5). The removal is to be performed on one side only.

AQ13002-020

ASM-17-13-002

Issued 08-2008

Copyright © 5005-14 3) 1) Take-up roller (1) is reversed. 2) Remove the O-ring (4) from the shaft (5). 3) Pull out the shaft (5) from the take-up roller (1).

AQ13002-008

4) 1) Remove the spring pin (6) from the shaft (5) (or hub (9). 2) Remove the hub (9) from the shaft (5). 3) Remove the O-ring (4) from the shaft (5).

AQ13002-009

5) Remove the floating seals (3) from the hubs (7),(9).

AQ13002-010

6) Remove the floating seals (3) from the take-up roller (1).

AQ13002-011

ASM-17-13-002

Issued 08-2008

Copyright © 5005-15 7) Remove the bushings (2) from the take-up roller (1) using pulling jigs, press and other instruments. NOTE: Do not attempt to disassemble bushings (2) unless they are unusable due to wear.

AQ13002-012

8) Cleaning parts 1) Place parts in the preparatory cleaning container containing cleaning oil. NOTE: Wash off deposited substances which may cause scratches. NOTE: Leave the parts submerged in the kerosene until the dirt and grease come off and float up 2) Put the parts in the finish cleaning container containing cleaning oil and wash them by slowly moving them. 3) Wipe off remaining cleaning oil with clean cloth. NOTE: Place the parts somewhere free of dust and moisture, and dry them using compressed air. After drying, apply engine oil to the parts.

ASM-17-13-002

Issued 08-2008

Copyright © 5005-16 4 Assembling instructions [1] Prior to assembly • Clean all the parts. • Polish scratches, flashes or burrs using oil stones. • Change sealing parts such as O-rings with new ones. [2] Assembling procedure 1) Install bushings (2) to the take-up roller (1) using a jig and hammer. NOTE: Pay full attention when inserting the bushings (2) by hammering. Do not reuse bushings (2).

AQ30002-013

AQ30002-014

2) Install the floating seals (3) to take-up roller (1). apply grease to the floating seals. NOTE: Do not reuse floating seals (3).

AQ13002-011

ASM-17-13-002

Issued 08-2008


AQ30002-015

3) Install the floating seals (3) to the hubs (7), (9). NOTE: Do not reuse floating seals (3).

AQ13002-010

AQ30002-016

4) 1) Install the greased O-ring (4) to the shaft (5). The installation is to be performed on one side only. 2) Install the shaft (5) to the hub (9) and secure them with a spring pin (6). NOTE: Do not reuse spring pin (6) and O-ring (4).

AQ13002-022

ASM-17-13-002

Issued 08-2008

Copyright © 5005-18 5) 1) Apply grease on the surface of the shaft. 2) Install the shaft (5) to the take-up roller (1). 3) Install the greased O-ring (4) to the shaft (5). NOTE: Do not reuse O-ring (4).

AQ13002-021

6) Install the hub (7) to the shaft (5) and secure them with a spring pin (6). NOTE: Do not reuse spring pin (6).

AQ13002-020

7) Check for leakage in the assembly using compressed air. Compressed air pressure: 0.2 MPa

AQ13002-017

8) Fill oil through the plug.

AQ13002-018

ASM-17-13-002

Issued 08-2008

Copyright © 5005-19 9) Install the plug (8). NOTE: Clean the assembly and dry it using compressed air.

AQ13002-019


ASM-17-13-002

Issued 08-2008


-##<%

1. 2. 3. 4. 5.

Track-up roller (1) Bushing (2) Floating seal (2) O-ring 1B P36 (2) Roller shaft (1)

ASM-17-13-002

6. 7. 8. 9.

Spring pin (2) Hub (with plug) (1) Plug 1/8 (1) Hub (without plug) (1)

Issued 08-2008

6001

Copyright ©

Section 6001 REMOVAL AND INSTALLATION OF THE DRIVE MOTOR AND FINAL DRIVE TRANSMISSION

CNH

Lep SM75SR6001-0EN


Copyright © 6001-2

TABLE OF CONTENTS TRAVEL UNIT.......................................................................................................................................................... 3 Precautions when installing............................................................................................................................... 3 Removal ............................................................................................................................................................ 4 Installation ......................................................................................................................................................... 5

Lep SM75SR6001-0EN

Issued 08-2008

Copyright © 6001-3

TRAVEL UNIT

8 7

6 AQ10002-012

1. 2. 3. 4.

Travel motor Bolt Loctite 262 Drive sprocket

5. 6. 7. 8.

Bolt Drain port Oil level check port Oil fill port

1 Precautions when installing [1] Be careful of direction when attaching sprockets to the machine. The side having the C2 chamfer of the sprocket must face the traction motor. [2] Coat the threads with loctite 262 or equivalence, and fasten them by tightening torque. [3] When starting the machine after assembling, bleed the air from the upper drain port (6). [4] Set the reduction gear as shown in the follewing fig when checking and filling the oil. (The lowest point of oil level port (7) is the standard oil level.) [5] When changing the reduction gear oil, remove drain plugs from the reduction gear side, and let the oil drain out. Next, screw the plugs back in and fill the oil the normal oil level.

ASM-17-10-002

Issued 08-2008

Copyright © 6001-4 2 Removal [1] Remove track shoe. See “Track shoe, removal”. [2] Lift one side of lower frame about 200 mm and hold it there. (Lift it high enough for the drive sprocket to be removed from the track shoe). [3] Place protection blocks under lower frame and secure them. [4] Stop engine and release pressure in the hydraulic circuits. (See the procedures for bleeding the hydraulic pressure in Operator’s Manual). [5] Remove motor cover. AQ10002-013

[6] Remove drive sprocket mounting bolts (2). [7] Separate drive sprocket (4) from mounting flange on travel unit using a steel bar. [8] Attach a lifting tool onto the drive sprocket.

AQ10002-014

[9] Using the lifting tool, lift the drive sprocket and remove it from the travel unit. [10]Attach marking tags to the travel motor hoses to tell them apart when they are reconnected. [11]Remove the hoses and put bull plugs or caps on them to keep out dust. [12]Attach the lifting tool onto the travel unit. NOTE: Lift the travel unit until the wire on the lifting tool is tense. AQ10002-015

[13]Remove travel unit mounting bolts (5). [14]Remove travel unit using a steel bar.

AQ10002-016

ASM-17-10-002

Issued 08-2008

Copyright © 6001-5 3 Installation [1] Lift travel unit and align it so that it fits on the frame. (Be careful of the fitting angles.). [2] Apply Loctite No. 262 to threads of travel unit mounting bolts (5) and finger tighten all mounting bolts.

Bolt tightening order: Tighten the four numbered bolts evenly in the sequence shown below and then fasten the remaining bolts.

[3] Tighten travel unit mounting bolts (5) to the specified torque alternatively, up/down and left/right, so that the tightening force acts on them equally. (Refer to Tightening torque in the Maintenance Instructions.) [4] Lift drive sprocket and confirm that it is oriented correctly. [5] Align drive sprocket to mounting flange on the travel unit using a steel bar. [6] Apply Loctite No. 262 to threads of drive sprocket mounting bolts (2), and finger tighten all mounting bolts.

AQ10002-017

[7] Tighten drive sprocket mounting bolts (2) to the specified torque alternatively, up/down and left/right, so that the tightening force acts on them equally. (Refer to Tightening torque in the Maintenance Instructions.) [8] Connect hoses to travel motor. [9] Check reduction gear oil level. Fill if necessary. [10]Bleed air from travel motor. (Fill motor with hydraulic oil) [11]Remove protection blocks. [12]Lower the lower frame on the track shoe. [13]Install track shoe. See “Track shoe, installation”. [14]Check to ensure that there is no oil leakage. If leakage is found, take appropriate measures. [15]Install motor cover.

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Copyright © 6001-6

NOTES .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... 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ASM-17-10-002

Issued 08-2008

6002

Copyright ©

Section 6002 DISASSEMBLY AND ASSEMBLY OF THE DRIVE MOTOR AND FINAL DRIVE TRANSMISSION

CNH

Lep SM75SR6002-0EN


Copyright © 6002-2

TABLE OF CONTENTS TRAVEL UNIT.......................................................................................................................................................... 3 SERVICE OUTLINE.................................................................................................................................................. 3 Tools ................................................................................................................................................................. 3 Tightening torque table ..................................................................................................................................... 7 Weight table ...................................................................................................................................................... 7 DISASSEMBLY ....................................................................................................................................................... 8 Preparations. ..................................................................................................................................................... 8 General suggestion when working .................................................................................................................... 8 Disassembly procedure..................................................................................................................................... 9 SERVICE PREPARATION ....................................................................................................................................... 26 ASSEMBLY .......................................................................................................................................................... 28 PERFORMANCE CONFIRMATION TEST.................................................................................................................... 44 Required measuring devices........................................................................................................................... 44 Test procedure ................................................................................................................................................ 44 EXPLODED DIAGRAM OF REDUCTION GEAR ........................................................................................................... 45 EXPLODED DIAGRAM OF HYDRAULIC MOTOR......................................................................................................... 46 INTERNAL STRUCTURE DIAGRAM .......................................................................................................................... 47 TRAVEL UNIT PART TABLE ................................................................................................................................... 48

Lep SM75SR6002-0EN

Issued 08-2008

Copyright © 6002-3

TRAVEL UNIT 1 Service outline 1 Tools 1) Standard tools No

Name

Description and remarks

Q’ty

1

Hexagon wrench

3, 6, 10, 12 mm

One of each

2

Socket wrench (ratchet handle) (JIS B 4641)

Barrel type

1

3

Torque wrench (JIS B 4650)

Dial type, approx. 12 N Dial type, approx. 90 N Dial type, approx. 150 N Dial type, approx. 600 N

1 1 1 1

4

Torque wrench adapter

Nominal socket 13, 30 Nominal rod size 3, 6, 8

One of each

5

Hexagon socket

Opposite side 13, 17, 24, 36 mm

One of each

6

Extension bar (JIS B 4637)

150 mm

1

7

Hand hammer

Nominal 12 mm

1

8

Plastic hammer

About L = 300 mm

1

9

Flat-blade screwdriver (JIS B 4609)

50 mm 150 mm

1 1

10

Snap ring pliers

For shafts For holes

1 1

11

Cutting pliers (JIS B 4623)

200 mm

2

12

Lifting tool (crane)

Lifting load 2940 N or more Eyebolt (For PF3/8) Wire with hook

1 2 1

13

Receptacles

Volume: W450 x D300 x H120

2

14

Leather gloves

1 pair

2) Bolts No 1

Name Hexagon socket head bolt (JIS B 1176)

ASM-17-21-002

Description Approx. M6 (P1.0) x 50 Approx. M16 (P2.0) x 40 Approx. M16 (P2.0) x 150

Q’ty 1 2 3

Issued 08-2008

Copyright © 6002-4 3) Equipment and materials Applicable parts (Usage method or parts No.) For disassembling and reassembling works

Name


Q’ty

General work bench

1

For washing motor and parts

Washing tank

1

104, 149

Press machine

Press capacity: 1960 N or more

1

Heating tank

Heating capacity: over 100°C Volume: 500 x 500 x 500 mm

1

Compressed air supply

Pressure: 0.29 - 0.49 MPa

149 For drying washed parts 4) Manufacturing tools Name: Travel motor workbenchp

• Workbench for easily and safely disassembling and assembling the travel motor.

AQ21002-001

Name: Fixture • For connecting spindle (2) and hub (1).

AQ21002-002

Name: Holder ( I ) • For inserting spring (114), washer (110) and snap ring (145) into cylinder block (104). • For removing spring (114) from cylinder block (104). AQ21002-003

Name: Holder ( II ) • For removing ball bearing (149) from or insertingit onto shaft (102).

AQ21002-004

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Copyright © 6002-5 Name: Holder ( III ) • For press fitting oil seal (132) into the oil seal holethe spindle (2).

AQ21002-005

Name: Press tool • For press fitting ball bearing (24) into hub (1).

AQ21002-006

Name: Steel rod ( I ) • For removing ring (45) from hub (1).

AQ21002-007

Name: Bearing preload adjuster • For fitting ring nut (22) to spindle (2).

AQ21002-008

Name: Eyebolt • For lifting the GM motor, spindle (2) and hub (1). “A”: Hub, M14 Spindle, M16 GM motor, M16 AQ21002-009

Name: Slice • For removing timing plate (109) from rear flange (301).

AQ21002-010

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Issued 08-2008

Copyright © 6002-6 Name: Aluminium rod • For removing the outer race of ball bearing (24).

AQ21002-011

Name: Cover removable jig • For removing cover (13) from hub (1).

AQ21002-012

Name: Floating seal installation tool ( I ) • For installing floating seal (31) to hub (1).

AQ21002-013

Name: Floating seal installation tool ( II ) • For installing floating seal (31) to hub (1) and spindle (2).

AQ21002-014

Name: Floating seal installation tool ( III ) • For installing floating seal (31) to spindle (2).

AQ21002-015

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Copyright © 6002-7 Name: Thrust washer installation tool (carrier(3)) • For installing three thrust washers 3 (12) to the carrier (3) with hexagon head bolt.

AQ21002-016

Name: Thrust washer installation tool (spindle(2)) • For installing four thrust washers 1 (10) to the spindle (2) with hexagon head bolt.

AQ21002-017

2 Tightening torque table Bolt/Nut used

Part No. (structure drawing)

Part name

Nominal designation

Width across flats (mm)

Q’ty

Tightening torque (Nm)

33

Plug

PF3/8

8

1

58.8 ± 9.81

39

Socket plug

PF3/8

8

2

58.8 ± 9.81

40

Hexagon head bolt

M8 (P1.25)

13

7

33.3 ± 4.9

47

Hexagon socket set screw

M6 (P1.0)

3

2

4.9 ± 0.98

51

Hexagon socket set screw

M6 (P1.0)

3

2

4.9 ± 0.98

221

Plug

PF1/4

6

2

29.4 ± 4.9

224

Plug

M25 (P1.5)

30

2

196 ± 44.7

226

Plug

M20 (P1.5)

8

2

78.5 ± 9.81

243

Hexagon socket head cap screw

M8 (P1.25)

6

6

29.4 ± 4.9

3 Weight table Applicable parts (structure drawing)

Name

Weight (kg)

-

Travel motor assembly

Approx. 53

1

Hub

Approx. 15

2

Spindle

Approx. 15

Rear flange assembly

Approx. 6.2

201

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Issued 08-2008

Copyright © 6002-8

2 Disassembly 1 Preparations. 1) Perform the following preparations before disassembling. 1) Workbench preparations Provide a travel motor workbench. Provide a sturdy workbench with which the internal parts of the travel motor can be disassembled or assembled, is wide enough to place parts so they do not move or fall off the bench while working. Spread a rubber or vinyl sheet on the workbench. 2) Preparation of tools and materials. Provide the tools and materials listed in 1.Tools. 2 General suggestion when working

!

WARNING: Internal parts are coated with hydraulic fluid and gear oil during disassembly and are slippery. If a part slips out of your hand and falls, it could result in bodily injury or could damage the part. Be very careful when handling.

!

WARNING: Combustibles such as white kerosene are used for washing parts. These combustibles are easily ignited, and could result in fire or injury. Be careful when handling.

[1] Before disassembling, perform inspections and clearly determine the nature of any abnormalities which might be occurring, and work according to the disassembly procedure. [2] Each part is manufactured to extreme precision. Handle with care and be sure not to hit the parts together or drop them. [3] When working, do not attempt to forcefully beat or wrench tightly fitting parts. Doing so could produce burrs or damage the parts so they can’t be mounted or may reduce their performance. You should exercise patience when working. [4] If you leave parts disassembled or partially disassembled, rust could develop on the parts due to moisture or dirt. If you have to interrupt work before completion, be careful to take measures to protect against rust or dust. [5] Place a counter mark on mating faces of parts when disassembling. [6] Arrange removed parts neatly when disassembling so as not to damage or lose the parts while working. [7] As a rule, once any type of seal is disassembled it should be replaced with a new one even if it shows no signs of damage. You should have a new ready when disassembling. [8] The photographs and drawings contained in the manual are of representative models. Disassembly procedure is however not affected even if the product you are using differs in part.

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Issued 08-2008

Copyright © 6002-9 3 Disassembly procedure [1] Washing the GM motor 1) Fasten the eyebolts to spindle (2). NOTE: Fasten the two eyebolts in the screw holes for mounting the spindle so they are positioned symmetrically.

AQ21002-018

2) Hook the wire in the eyebolts, hoist the GM motor with a crane and carry to the washing tank. 3) Wash each part of the GM motor with a brush. NOTE: Earth and sand get in the clearance between hub (1) and spindle (2) (floating seal mounting section). Be sure to wash this part with special care.

AQ21002-019

[2] GM motor installation. 1) Set the GM motor on a workbench. NOTE: While matching the screw holes of hub (1) and screw holes of the workbench, carefully place the travel motor in the mounting holes of the workbench.

AQ21002-020

2) Mount the GM motor on the workbench so that the two hexagon socket head cap screws are positioned symmetrically.

!

WARNING: Tighten the hexagon socket head cap screws securely. Failure to do so could result in injury cased by the GM motor falling when it is inverted.

AQ21002-021

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Issued 08-2008

Copyright © 6002-10 [3] Lubricating oil extraction NOTE: If disassembling the rear flange only, proceed to the item [8] Rear flange removal of page 12. 1) Invert the GM motor. (Turn up the side of reduction gear) 2) Loosen and remove plug (33) and socket plug (39). NOTE: When extracting the lubricating oil, place a container under the workbench. AQ21002-022

3) Invert slowly the GM motor and extract the lubricating oil. (Turn up the side of motor) 4) Remove O-ring (37) from plug (33) and socket plug (39). NOTE: Do not reuse O-rings (37) which have been removed.

AQ21002-023

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

AQ21002-024

4) Place a block against two bolts outside of the cover removal jig and tighten the bolts to allow the cover (13) to come off little by little. NOTE: In case of the cover (13) is hard to remove because of resistance of O-ring (35), lift it up while lightly tapping the outer rim of the cover by a plastic hammer. 5) Remove O-ring (35) from hub (1). NOTE: Do not reuse O-ring (35) which has been removed.

AQ21002-025

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Issued 08-2008

Copyright © 6002-11 [5] Sun gear 1 removal 1) Remove sun gear 1 (4). 2) Remove steel ball (41) from the sun gear 1 (4).

AQ21002-026

[6] Carrier assembly removal 1) Remove the carrier assembly from hub (1). NOTE: The carrier assembly may pull out together with thrust collar 1 (9).

AQ21002-027

2) Disassemble carrier assembly 1. Loosen three hexagon head bolts (40) and remove them from carrier (3). 2. Remove thrust washer 3 (12) (3 pcs), planetary gear 1 (5) (3 pcs), needle roller bearing (27) (3 pcs), and inner ring (29) (3 pcs) from carrier (3).

AQ21002-028

3) Remove retaining ring (50) from sun gear 2 (6). 4) Remove sun gear 2 (6) from carrier (3).

AQ21002-029

ASM-17-21-002

Issued 08-2008

Copyright © 6002-12 [7] Planetary gear 2 removal 1) Loosen hexagon head bolt (40) (4 pcs) and remove them from spindle (2).

AQ21002-030

2) Remove planetary gear 2 (7) (4 pcs), needle roller bearing (28) (4 pcs) and inner ring (30) (4 pcs). 3) Remove thrust washer 2 (11) (4 pcs) from spindle (2). 4) Remove thrust collar 1 (9) from spindle (2).

AQ21002-031

[8] Rear flange removal 1) Turn the workbench so rear flange (301) is on top. NOTE: This work is carrying out to remove easily the plugs at the next work. Do not loosen the bolts if the rear flange inside is not disassembled. 2) Temporarily loosen sleeve (203) (2 pcs).

AQ21002-032

3) Temporarily loosen plug (324) (2 pcs).

AQ21002-033

ASM-17-21-002

Issued 08-2008

Copyright © 6002-13 4) Temporarily loosen plug (382) (2 pcs).

AQ21002-034

5) Temporarily loosen plug (382).

AQ21002-035

6) Loosen and remove hexagon socket head cap screw (345) (8 pcs) from rear flange (301).

AQ21002-036

7) Remove rear flange (301) from spindle (2). NOTE: Hold the rear flange by both hands, hold it up gently upright to remove it. Perform the work with care not to forcibly pry or strike the flange. Otherwise it may cause the timing plate (109) to drop and be damaged.

AQ21002-037

ASM-17-21-002

Issued 08-2008

Copyright © 6002-14 8) Pull out parallel pin (42) (2 pcs) from spindle (2).

AQ21002-038

9) Remove O-ring (43) (2 pcs), (44) from spindle (2) NOTE: Do not reuse O-ring (43), (44) which have been removed.

AQ21002-039

[9] Disassembly of the rear flange mounting the parts 1) Lay removed rear flange (301) on the workbench. (Face up the mating face with spindle (2)). 2) Remove timing plate (109) from rear flange (301). NOTE: The timing plate might be found stuck to the mating face of the rear flange. To separate timing plate, insert a flat bar into the groove of the rear flange and raise the timing plate slowly. Never try to ply the timing plate off with a sharp or pointed tool or the precision finished mating faces will suffer costly damage. AQ21002-040

3) Pull out parallel pin (342) from rear flange (301).

AQ21002-041

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Issued 08-2008

Copyright © 6002-15 4) Pull out deep groove ball bearing (150) from rear flange (301).

AQ21002-042

[10] Disassemble SRV into rear flange 1) Remove sleeve (203) (2 pcs) from rear flange (301).

AQ21002-043

2) Remove O-ring (207) and backup ring (208) from valve seat (202) one by one. NOTE: Do not reuse O-ring (207) and backup ring (208) which has been removed.

AQ21002-044

3) Remove O-ring (212) from sleeve (203). NOTE: Do not reuse O-ring (212) which has been removed.

AQ21002-045

ASM-17-21-002

Issued 08-2008

Copyright © 6002-16 [11] Disassemble brake valve part into rear flange 1) Remove plug (324) (2 pcs) from rear flange (301).

AQ21002-046

2) Remove spring retainer (325) (2 pcs) and spring (328) (2 pcs) from rear flange (301). 3) Remove spool (323) from rear flange (301). NOTE: To remove spool (323), place your hand on one part of the plug port of the rear flange (301) and tilt it down. Then the spool (323) falls down. Hold the tip and remove it.

AQ21002-047

4) Remove O-ring (336) from plug (324). NOTE: Do not reuse O-ring (336) which has been removed.

AQ21002-048

5) Remove plug (382) (2 pcs) from rear flange (301).

AQ21002-049

ASM-17-21-002

Issued 08-2008

Copyright © 6002-17 6) Remove spring (330) (2 pcs) and valve (327) (2 pcs) from rear flange (301).

AQ21002-050

7) Remove O-ring (338) from plug (382). NOTE: Do not reuse O-ring (338) which has been removed.

AQ21002-051

[12] Removing pilot valve into rear flange 1) Remove plug (382) from rear flange (301). 2) Remove O-ring (338) from plug (382). NOTE: Do not reuse O-ring (338) which has been removed.

AQ21002-052

3) Remove spool (363) and spring (366) from rear flange (301).

AQ21002-053

ASM-17-21-002

Issued 08-2008

Copyright © 6002-18 [13] Disassembly of the parking brake

!

WARNING: The abrupt injection of compressed air could cause the piston (112) to pop out. To ensure your safety hold a protective cover over the piston (112). 1) Remove piston (112) from spindle (2) by injecting compressed air into the access hole in the spindle (2). 2) Remove O-ring (135), (139) from piston (112).

NOTE: Do not reuse O-ring (135), (139) which have been removed.

AQ21002-054

3) Remove spool (363) and spring (366) from rear flange (301).

AQ21002-055

[14] Disassembly of the Hydraulic motor NOTE: Place an oil receptacle just below the motor to catch the oil. 1) Turn the GM motor 90 degrees. 2) Drain the hydraulic oil from the motor. 3) Take out mating plate (116) (3 pcs) and friction plate (115) (2 pcs).

AQ21002-056

4) Hold the cylinder block (104) by hand, turn alternately 2 - 3 times, and cut off shoe (106) adhered on the swash plate (103). NOTE: If remove the cylinder block (104) as-is, shoe (106) remains adhered on swash plate (103), and the parts (piston, shoe and etc.) mounted on the cylinder block will come off the cylinder block and fall into the spindle (2).

AQ21002-057

ASM-17-21-002

Issued 08-2008

Copyright © 6002-19 5) Draw out cylinder block (104) from shaft (102). 6) Remove the piston ASSY ( piston (105), shoe (106) ) and retainer plate (107) ) from cylinder block (104). NOTE: When removing the piston ASSY, grip retainer plate (107) with both hands and remove together with the retainer plate. The piston ASSY is a minimum unit. If replacement is necessary, replace the piston ASSY as one unit. AQ21002-058

7) Remove piston ASSY (9 pcs) ( piston (105), shoe (106) ) from retainer plate (107).

AQ21002-059

8) Remove thrust ball (108) from cylinder block (104).

AQ21002-060

9) Remove washer (111) needle roller (151) (3 pcs) from cylinder block (104).

AQ21002-061

ASM-17-21-002

Issued 08-2008

Copyright © 6002-20 [15] Removal of the spring inside the cylinder block 1) Place cylinder block (104) on the press bench. NOTE: The spring is removed only when replacing. The spring is removed by lining up the shaft centers of holder ( I ) (A) and washer in order to prevent damage to the cylinder block through contact. Cover the cylinder block with a vinyl sheet to prevent the sliding surfaces of the cylinder block from being damaged.

AQ21002-062

2) Place holder ( I ) on the washer (110), and while clamping the holder with the press, remove snap ring (145) with a snap ring pliers.

!

WARNING: Release press slowly. Sudden releasing may cause spring to fly out incurring the danger of injury.

AQ21002-063

3) Remove snap ring (145), washer (110),spring (114) and washer (110) from inside cylinder block (104).

AQ21002-064

[16] Removal of the swash plate 1) Take out swash plate (103) from shaft (102). NOTE: When removing the swash plate (103), ensure that pivot (167) is not adhered on the swash plate.

AQ21002-065

ASM-17-21-002

Issued 08-2008

Copyright © 6002-21 2) Pull shaft (102) out of spindle (2). Then deep groove ball bearing (149) is removed together. NOTE: Be careful to lightly strike the tip of the shaft on the reduction side using a plastic hammer to allow the shaft to come off easily. Otherwise the shaft may pop out.

AQ21002-066

3) Take out pivot (167) (2 pcs) and parallel pin (177) (2 pcs) from spindle (2). 4) Blow compressed air through passage of the spindle (2). Take out the 1st/2nd speed piston kit and spring (190) from spindle (2). Piston (161) + shoe (162) = piston assembly.

AQ21002-067

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

AQ21002-068

[18] Removal of the ring nut 1) Fix hub (1) and spindle (2) with the fixture. The fixture should be tightened in symmetrical positions with each other. 2) Invert the GM motor. (The side of reduction gear is turned up).

AQ21002-069

ASM-17-21-002

Issued 08-2008

Copyright © 6002-22 3) Remove hexagon socket set screw (47) (2 pcs).

AQ21002-070

4) Loosen ring nut (22) with the bearing preload adjuster (C). NOTE: Do not reuse removed ring nut (22).

AQ21002-071

AQ21002-072

5) Take out ring nut (22) from spindle (2).

AQ21002-073

ASM-17-21-002

Issued 08-2008

Copyright © 6002-23 [19] Removal of the ring nut 1) Invert the GM motor. (Turn up the side of motor). 2) Remove the fixture. 3) Fasten the eyebolt (2 bolts, for M16) in the mounting holes of spindle (2) so they are symmetrically positioned. 4) Hook the hook on the eyebolts, gently and slowly hoist with a crane and remove spindle (2) from hub (1). At this time, floating seal (31) and oil seal (132) come off together.

AQ21002-074

[20] Ball bearing removal 1) Remove floating seal (31) from hub (1). NOTE: Do not reuse floating seal (31) which has been removed.

AQ21002-075

2) Tapping the end face of ball bearing (24) with aluminum rod (pin punch) and hammer, remove the ball bearing from hub (1). NOTE: When the fit section of the outer race of ball bearing (24) comes out of hub (1), the ball bearing (24) drop from the hub (1). Therefore place a receptacle under the workbench and spread a rubber mat on the receptacle so as not to damage the parts. 3) Turn over the travel motor. 4) Tapping the end face of outer race of ball bearing (24) with aluminum rod (pin punch) and hammer, remove the ball bearing from hub (1).

AQ21002-076

NOTE: Remove ball bearing (24) little by little, tapping evenly the end face of outer race of the ball bearing at 3 or 4 points so that the ball bearing is not suck.

ASM-17-21-002

Issued 08-2008

Copyright © 6002-24 [21] Removal of the spindle fittings 1) Remove floating seal (31) from spindle (2).

AQ21002-077

2) Remove oil seal (132) from spindle (2). NOTE: Do not reuse floating seal (31) and oil seal (132) which have been removed.

AQ21002-078

[22] Washing 1) Separate hub (1), spindle (2), cover (13) and rear flange (301) from other parts. (hereafter called the built-in parts). 2) Wash the built-in parts in a wash tank. NOTE: Carefully wash to remove any darts from the external surfaces.

AQ21002-079

!

WARNING: Wash all parts carefully with kerosene. Take notice of a possibility of due to combustibility. To prevent the built-in parts from being marred by dirt during washing, immerse the parts in kerosene long enough for any dirt or oil to become loose and surface before washing them, 3) Full a primary washing vessel with kerosene. Put the built-in parts in it and wash them.

AQ21002-080

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Issued 08-2008

Copyright © 6002-25 [23] Finish washing 1) Rinse the washed parts in the rinsing sink filled with clean kerosene by gently shaking each parts in the kerosene. 2) Using clean, list-free cloth, wipe each rinsed part to remove dripping kerosene. NOTE: Dry the inside of hub (1) and spindle (2) by spraying with compressed air until they are dray and clean. Let other parts dry naturally until they are dry and clean. After drying, coat every part with oil. AQ21002-081

ASM-17-21-002

Issued 08-2008


3 Service preparation Follow these standards when disassembling and inspecting the GM motor. Handle the various parts carefully. Be especially careful not to damage the moving and sliding parts. 1) Seals Once disassembled, all seals (O-rings, oil seals, floating seals) should be replaced with new ones even if no damage is observed. 2) Service standards for parts subject to wear 1) Replace all parts which show striking damage. 2) Replace if various parts have the following problems (phenomenon). No

Part name

Phenomenon

Standard

Service limit

(1)

Hub

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

-

-

(2)

Spindle

Serious damage in appearance. Abnormal wear such as scuffing.

-

-

(3)

Carrier assembly

Abnormal wear such as scuffing.

-

-

(4) (6) (5) (7)

Sun gear 1 Sun gear 2 Planetary gear 1 Planetary gear 2

Pitting on tooth surface. Flaking phenomenon on rolling surface of bearing.

-

-

(9) (11) (12)

Thrust washer 1 Thrust collar 4 Thrust washer 3

Sliding surface is tarnished.

-

-

(24)

Ball bearing

Has indentation. Exhibits flaking phenomenon. Worn unequally.

-

-

(27) (28)

Needle roller bearing

Pitting phenomenon on roller. Cage end face has abnormally worn.

-

-

(29) (30)

Inner ring

Exhibit flaking phenomenon on rolling face of bearing.

-

-

(301)

Rear flange

Flaw on sliding part with spool (323).

-

-

(102)

Shaft

Working face with oil seal (132) is worn. Spline is worn.

-

-

(103)

Swash plate

Has burning phenomenon.

-

-

(104)

Cylinder block

Spline section is worn. Inner surface of bore is worn too much. Flaw and wear on sliding surface with timing plate (109).

-

-

(105) (106)

Piston assembly Piston Shoe

Clearance is found in the axial direction between piston (105) and shoe (106). Shoe is abnormally worn and nequally worn.

Clearance 0.05 mm

Clearance 0.15 mm

ASM-17-21-002

Issued 08-2008

Copyright © 6002-27 No

Part name

Phenomenon

Standard

Service limit

(107)

Retainer plate

Sliding part with shoe (106) is worn unequally. Flaw and unequal wear on sliding surface with thrust ball (108).

-

-

(108)

Thrust ball

Ball surface sliding part with retainer plate (107) is worn unequally.

-

-

(109)

Timing plate

Sliding surface has burning phenomenon and unequal wear.

-

-

(115) (116)

Friction plate Mating plate

Both end faces are unequally worn. Torque is not specified torque. Has burning phenomenon.

Braking torque 120 Nm or more

Braking torque 120 Nm or more

(105)

Piston

Flaw on circumference

-

-

(149) (150)

Deep groove ball bearing

Has indentation. Exhibits flaking phenomenon. Worn unequally.

-

-

(161) (162)

Dual speed piston kit Piston Shoe

Circumference is abnormally worn. Shoe is abnormally worn and unequally worn.

-

-

(323) (363)

Spool

Circumference worn unequally. Flaw on circumference.

-

-

ASM-17-21-002

Issued 08-2008


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

ASM-17-21-002

Issued 08-2008

Copyright © 6002-29 [1] Hub section reassembly 1) Place hub (1) on the press bench. 2) Insert the ball bearing (24) into hub (1). Place a press tool (A) on the peripheral rim of ball bearing (24) and press it and fit the ball bearing into the hub little by little. 3) Turn the hub (1) upside down. 4) Insert ball bearing (24) into hub (1) in the same way. NOTE: Make sure that the installing direction ofball bearing (24) is correct.

AQ21002-082

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

AQ21002-083

6) Fasten two eyebolts in the screw holes of hub (1) so they are symmetrically positioned. 7) Hook the hook and wire in the eyebolts, hoist the hub (1) with a crane, and set the hub (1) on the workbench. NOTE: While matching the screw holes of hub (1) and mounting holes of the workbench, place the hub gently in the mounting holes of the workbench.

AQ21002-084

8) Fasten hub (1) to the workbench so that the hexagon socket bolts are symmetrically positioned.

!

WARNING: Tighten the hexagon socket bolts securely. WARNING: Failure to do so could result in injury if the travel motor is inverte

AQ21002-085

ASM-17-21-002

Issued 08-2008

Copyright © 6002-30 [2] Spindle assembly 1) Apply grease thinly on the outside circumference of the O-ring of floating seal (31) and mount the floating seal in the floating seal groove of spindle (2). NOTE: To mount the floating seal, place the floating seal installation tool ( III ) (E), floating seal and floating seal installation tool ( II ) (D) in that order, and press in until floating seal installation tool ( II ) reaches floating seal installation tool ( III ). Remove the installation tools, and check the inclination of the surface of the floating seal to make sure it is within 1 mm. AQ21002-086

2) Install eyebolts to spindle (2) so they are symmetrically positioned. 3) Hook a wire with hook to eyebolts, lift the spindle (2) by crane, and then insert the spindle in hub (1) slowly.

AQ21002-087

4) Fix hub (1) and spindle (2) with the fixture in diagonal position.

AQ21002-088

5) Invert the GM motor. (Turn up the side of reduction gear). 6) Apply Loctite 638 to the thread part of ring nut (22). 7) The ring nut to the spindle (2) with the bearing preload adjuster (F). Then, fit the ring nut (22) to the spindle (2) so that a side with large camfering may be on a ball bearing (24) side. Tightening torque: 588 ± 55.8 Nm AQ21002-089

ASM-17-21-002

Issued 08-2008

Copyright © 6002-31 8) Tighten hexagon socket set screw (47) (2 pcs) with specified torque. Tightening torque : 9.81 ± 1.60 Nm 9) After tightening up the screws, deform the entrance of the threaded holes for avoiding loosening screws.

AQ21002-090

10) Inver the GM motor. (Turn up the side of motor) 11) Remove the fixture.

AQ21002-091

[3] Assemblng spindle fittings 1) Press fit oil seal (132) into spindle (2) with the holder ( III ) (E) and a hammer. NOTE: Apply lithium grease the lip section of the oil seal when mounting the oil seal. Press oil seal (132) bore to spindle (2) using the holder ( III ) and hammer.

AQ21002-092

2) Install parallel pin (177) (2 pcs) into the pin holes of the spindle (2). 3) Apply lithium grease to the hemispherical surface of pivot (167) (2 pcs), and fit it into parallel pin (177) of spindle (2). 4) Apply lithium grease to spring (190), and install the spring into the piston kit (piston (161), shoe (162)). 5) Apply hydraulic fluid to the sliding surface of the piston ASSY, install it into the piston hole of spindle (2). AQ21002-093

ASM-17-21-002

Issued 08-2008

Copyright © 6002-32 [4] Installing shaft

!

WARNING: Wear thick leather grooves in handling the heated deep groove ball bearing. 1) Put deep groove ball bearing (149) in a heating tank to heat it at 100 ± 10°C for ten minutes, it puts on the holder ( II ) (D), it does shaft (102) at the press fitting by the press.

AQ21002-094

2) Fit motor shaft (102) slowly into the spindle (2). 3) Turn the workbench 90 degrees. NOTE: Take care not to scratch or cut the lip portion of the oil seal in place with the splined foremost end of the shaft.

AQ21002-095

4) Install swash plate (103) to spindle (2). NOTE: Apply lithium grease to the swash plate (103) where mating surface of the spindle (2). Make sure that the locating the pivot (167) of the spindle (2) enters the pivots hole of the swash plate (103).

AQ21002-096

ASM-17-21-002

Issued 08-2008

Copyright © 6002-33 [5] Assembly of cylinder block interior NOTE: Introduce the sharp side of the angled section of the THS snap ring (145) and washer (110) as shown in the figure on the left. 1) Insert washer (110), spring (114), washer (110) and snap ring (145) in that order into cylinder block (104). 2) Place cylinder block (104) on the press bench.

AQ21002-097

!

WARNING: Press force of spring (114) is 1180 N or more. Protect by covering cylinder block (104) with a vinyl sheet so the contact surface with timing plate (109) of cylinder block (104) does not become damaged. 3) Place holder ( I ) on washer (110), and while clamping with press, fit snap ring (145) in the snap ring groove of cylinder block (104) with a snap ring pliers. AQ21002-098

[6] Assembly of the hydraulic motor parts 1) Place needle roller (151) (3 pcs) into the cylinder block (104) and place thrust ball (108) on the top.

AQ21002-099

2) Install the piston assembly (9 pcs) into the retainer plate (107). NOTE: After assembling, dip the whole thing in hydraulic fluid. 3) Fit retainer plate (107) and the piston assembly (9 pcs) into cylinder block (104). NOTE: Match the round surface sections of retainer plate (107) and thrust ball (108).

AQ21002-100

ASM-17-21-002

Issued 08-2008

Copyright © 6002-34 4) Install cylinder block (104) to shaft (102). NOTE: Install cylinder block (104) into the spline of shaft (102) by aligning the spline hole with the spline of the shaft.

AQ21002-101

5) After installing the cylinder block (102), turn it by hand and make sure that it fits properly. If not, inspect it. NOTE: After installing the cylinder block (104), do not raise it. If it raises, thrust ball (108) separates and cylinder block do not rotates.

AQ21002-102

[7] Assembly of parking brake section NOTE: Install the friction plate to the cylinder block after immerse the friction plate (115) in hydraulic fluid. 1) Turn the workbench 90 degrees. 2) Install mating plate (116).

AQ21002-103

3) Friction plate (115) into the groove outside of cylinder block (104) alternately. Then install mating plate (116), friction plate (115) and mating plate (116). 4) Fit O-ring (135), (139) to the O-ring groove of piston (112). At this time, apply a thin coat of grease to the Orings. 5) Install piston (112) into spindle (2). NOTE: If the piston (112) doesnÕt fit into the spindle (2) because of the resistance of the O-rings, tap the edge of the piston (112) lightly and equally with a plastic hammer. Be careful not to damage the O-rings at this time

ASM-17-21-002

AQ21002-104

Issued 08-2008

Copyright © 6002-35 [8] Assembly of the brake valve parts in the rear flange 1) Fit O-ring (338) (2 pcs) to the plug (382) (2 pcs). NOTE: Apply grease to O-ring (338) (2 pcs). 2) Install valve (327) (2 pcs), and spring (330) (2 pcs) on rear flange (301). At this time, apply grease and on it to connect the valve (327), spring (330) and plug (382) by cohesion of the grease.

AQ21002-106

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

4) After inserting plug (382) (2 pcs), temporarily tighten into rear flange (301) by a hexagon wrench.

AQ21002-108

5) Insert spool (323) into rear flange (301). NOTE: Apply hydraulic fluid to the spool and insert the spool into the rear flange. To install the spool, align the hole of the rear flange with the spool shaft center so as to prevent the inner surface of the rear flange and the outer surface of the spool from being damaged due to interference. Otherwise internal leaks will occur after reassembly, resulting in performance deterioration of the travel motor.

AQ21002-109

ASM-17-21-002

Issued 08-2008

Copyright © 6002-36 6) Insert O-ring (336) into plug (324). NOTE: Apply grease to O-ring (336).

AQ21002-110

7) Install stopper (325) and spring (328) to the plug (324) (2 pcs). 8) Tighten plug (324) (2 pcs) into rear flange (301). NOTE: When tighten the plugs into the rear flange, insert carefully so as not to deform the spring. 9) Temporarily tighten two plugs (324) into rear flange (301) by spanner.

AQ21002-111

[9] Reassembling SRV part into rear flange 1) Attaches O-ring (207) and backup ring (208) onto valve sheet (201). 2) Attaches O-ring (212) onto sleeve (203). NOTE: Apply grease to O-ring (207), (212).

AQ21002-112

AQ21002-113

ASM-17-21-002

Issued 08-2008

Copyright © 6002-37 3) Insert sleeve (203) onto rear flange (301).

AQ21002-114

4) Temporarily tighten sleeve (203) (2 pcs) by spanner. NOTE: When thrusting plug into rear flange (301), insert plug carefully so that a spring may not change.

AQ21002-115

[10] Assembly of the rear flange mounted parts 1) Put rear flange (301) on the workbench, with its inner face up. 1) It unites as a spindle (2), a field is turned down, and a rear flange is placed. 2) Insert spring (366) and spool (363) into rear flange (301). NOTE: When thrusting plug into rear flange, insert plug carefully so that a spring may not change. AQ21002-116

3) Fit O-ring (338) to plug (382). NOTE: Apply grease to O-ring (338). 4) Tighten plug (382) into rear flange (301). 5) Temporarily tighten plug (382) into the rear flange (301). 2) Apply hydraulic fluid to deep groove ball bearing (150), and fit the deep groove ball bearing into rear flange (301). 3) Insert parallel pin (342) (2 pcs) in the pin holes of rear flange (301). 4) Apply grease to the mating face of timing plate (109) in contact with rear flange (301) of timing plate (109).

ASM-17-21-002

AQ21002-117

Issued 08-2008

Copyright © 6002-38 5) Fit timing plate (109) on rear flange (301) using parallel pin (342) and deep groove ball bearing (150) as a guide. NOTE: Fitting of timing plate (109) is carried out until the timing plate adheres to the rear flange (301). Adhesion prevents the timing plate (109) from falling from the rear flange (301) when mounting the rear flange (301) on spindle (2). 6) Install spring (113) (10 pcs) into rear flange (301). NOTE: Apply grease to the spring enough prevents the spring (113) (10 pcs) falling from the rear flange (301). AQ21002-118

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

AQ21002-119

2) Insert parallel pin (42) (2 pcs) into spindle (2). 3) Apply hydraulic fluid in timing plate (109) of cylinder block (104).

AQ21002-120

4) Install rear flange (301) onto spindle (2) so that two parallel pins (42) on the spindle enter the pinholes in the rear flange.

AQ21002-121

ASM-17-21-002

Issued 08-2008

Copyright © 6002-39 5) Tighten hexagon socket head cap screw (345) (8 pcs) equally and evenly with the specified torque. Tightening torque: 102 ± 15.7 Nm NOTE: When it installs rear flange (301) onto spindle, mount spring (113) (10 pcs) to rear flange side. Apply grease to the spring enough prevents the springs falling from the rear flange (301).

AQ21002-122

6) Tighten plug (382) with the specified torque. Tightening torque: 98.1 ± 19.6 Nm

AQ21002-123

7) Sleeve (203) with the specified torque. Tightening torque: 137 ± 14.7 Nm

AQ21002-124

8) Tighten plug (324) with the specified torque. Tightening torque: 353 ± 39.2 Nm

AQ21002-125

ASM-17-21-002

Issued 08-2008

Copyright © 6002-40 9) Tighten plug (382) with the specified torque. Tightening torque: 98.1 ± 19.6 Nm

AQ21002-126

[12] Carrier assembly 1) Insert sun gear 2 (6) on carrier (3), and insert retaining ring slot of sun gear 2 (6).

AQ21002-127

2) Install inner ring (29) (3 pcs), needle roller bearing thrust (27) (3 pcs), planetary gear 1 (5) (3 pcs) and washer 3 (12) (3 pcs) in that order to carrier (3). NOTE: If the tapped hole of carrier (3) is smeared oil or grease, degrease it by using the tap (M8 P1.25). After that clean it with solvent, and degrease the solvent of the holes by spraying with compressed air. Otherwise axial-force does not occur enough, and it may cause bolt to loosen. AQ21002-128

3) Install thrust washers 3 (12) (3 pcs) in that order to carrier (3) with installation tool (carrier (3)). 4) Install thrust washer 3 (12) (3 pcs) to the carrier (3) with hexagon head bolt (40) (3 pcs). Tightening Torque: 33.3 ± 4.9 Nm NOTE: When it do not use jig, be careful circumference of a companion of tighten thrust washer 3 (12). After tightening, check to rotate planetary gear smooth.

AQ21002-129

ASM-17-21-002

Issued 08-2008

Copyright © 6002-41 [13] Planetary gear 2 assembly 1) Turn the workbench upside down. (Turn up the side of reduction gear). 2) Install thrust collar 1 (9) to spindle (2).

AQ21002-130

3) Install thrust washer 2 (11) (4 pcs), finner ring (30) (4 pcs) to the pole of spindle (2). NOTE: It is careful in the inserting direction of four thrust washers 2 (11) (4 pcs).

Bigger chamfered or press droop

AQ21002-131

4) Install thrust washer 2 (11) (3 pcs) and inner race (30) (4 pcs) onto the pole of spindle (2). 5) Install needle roller bearing (28) (4 pcs) onto the pole of spindle (2). 6) Fit planetary gear 2 (7) (4 pcs) to each pole of spindle (2), meshing with internal teeth of hub (1). NOTE: If the tapped hole of spindle (2) is smeared oil or grease, degrease it by using the tap(M10 P1.5). After that clean it with solvent, and degrease the solvent of the holes by spraying with compressed air. Otherwise axial-force does not occur enough, and it may cause bolt to loosen.).

AQ21002-132

7) Install thrust washers 3 (12) (3 pcs) in that order to carrier (3) with installation tool (carrier (3)). 8) Install thrust washer 3 (12) (3 pcs) to the carrier (3) with hexagon head bolt (40) (3 pcs). Tightening Torque: 57.9 ± 9.81 Nm NOTE: When it do not use jig, be careful circumference of a companion of tighten thrust washer 3 (12). After tightening, check to rotate planetary gear smooth.

AQ21002-133

ASM-17-21-002

Issued 08-2008

Copyright © 6002-42 [14] Carrier assembly 1) Install the carrier ASSY, meshing with internal teeth of hub (1) and planetary gear 2 (7).

AQ21002-134

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

AQ21002-135

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

3) Install ring (45) in the ring groove of hub (1). NOTE: The free gap of ring (45) does not install onto the notch of hub (1).

AQ21002-137

ASM-17-21-002

Issued 08-2008

Copyright © 6002-43 4) Introduce 1.1 liters of lubricating oil into hub (1).

AQ21002-138

5) Fit O-ring (37) to plug (33) and socket plug (39). NOTE: Apply grease thinly to O-ring (37) thinly. 6) Tighten plug (33) and socket plug (39) with the specified torque to the cover (13). Tightening torque: 58.8 ± 9.8 Nm

AQ21002-139

[17] Remove the reassembled GM motor from the workbench 1) Turn the workbench upside down. 2) Remove the bolts securing the GM motor to the workbench. 3) Fasten two eyebolts to spindle (2). NOTE: Be sure that the two eyebolts are opposite to each other. 4) Hook the hook and wire on the eyebolts and remove the GM motor from the workbench with a crane.

ASM-17-21-002

AQ21002-140

Issued 08-2008


5 Performance confirmation test After servicing the GM motor, perform the following tests by the following procedure. 1 Required measuring devices

1

Pressure gauge for 3.43 MPa

2 pieces

2

Measuring cylinder (for 5 liters)

1 piece

3

Stop watch

1 piece

2 Test procedure

1

Installation and connection of travel motor

Install and connect the travel motor to the machine body (frame section). However, do not attach the track shoe. This is to perform the travel motor performance test (no-load operation) Note :

2

Travel motor breaking-in operation

• When connecting, connect the travel motor so that the pressure gauge (main circuit) can be installed and the drain amount of the hydraulic motor can be measured. • Whem installing GM motors, do not strike them with a hammer or other instrument. Use the bolt holes to gently install the motor.

Switching

Travel motor speed

Low speed rotation

10 min-1

High speed rotation

Pressure

Rotation direction

Operation time

No load

Left or right

Each 1 min. or longer

20 min-1

3

Travel motor performance confirmation test

1

Pre-test preparation operation • Perform preparation operation until the temperatures indicated below are reached. • Hydraulic oil temperature: 45~55°C • Reduction gear hub external temperature: 40~80°C

2

Confirmation test • Measure the items below at low speed to determine whether travel motor is acceptable. Criteria for acceptability Travel motor drive pressure difference: 1.57 MPa or less at 10 min-1 Hydraulic motor drain amount: 0.6 L/min at 10 min-1

Acceptable

Attach the track shoe

ASM-17-21-002

Not acceptable

Disassemble and adjust again

Issued 08-2008


6 Exploded diagram of reduction gear

AQ21002-0142

ASM-17-21-002

Issued 08-2008


7 Exploded diagram of hydraulic motor

AQ21002-0143

ASM-17-21-002

Issued 08-2008


8 Internal structure diagram

KAA10310-A01

ASM-17-21-002

Issued 08-2008


9 Travel unit part table Sym

Part name

Q’ty

Sym

Part name

Q’ty

Sym

Part name

Q’ty

1

Hub

1

103

Swash plate

1

208

Backup ring

4

2

Spindle

1

104

Cylinder block

1

211

O-ring

2

3

Carrier

1

105

Piston

9

212

O-ring

2

4

Sun gear 1

1

106

Shoe

9

213

Shim

2

5

Planetary gear 1

3

107

Retainning plate

1

214

Piston

2

6

Sun gear 2

1

108

Thrust ball

1

215

O-ring

2

7

Planetary gear 2

4

109

Timing plate

1

216

Backup ring

4

9

Thrust coller 1

1

110

Washer

2

301

Rear flange

1

10

Thrust washer 1

4

111

Washer

1

321

Plug

1

11

Thrust washer 2

4

112

Piston

1

323

Spool

1

12

Thrust washer 3

3

113

Spring

10

324

Plug

2

13

Cover

1

114

Spring

1

325

Spring retainer

2

22

Ring nut

1

115

Spring

2

327

Valve

2

24

Ball bearing

2

116

Mating plate

3

328

Spring

2

27


3

132

Oil seal

1

330

Spring

2

28


4

135

O-ring

1

336

O-ring

2

29

Inner ring

3

139

O-ring

1

338

O-ring

3

30

Inner ring

4

145

Snap ring

1

342

Parallel pin

1

31

Floating seal

2

149

Ball bearing

1

345

Hex. socket bolt

8

33

Plug

1

150

Ball bearing

1

352

Hex. socket plug

5

35

O-ring

1

151

Roller

3

363

Spool

1

37

O-ring

3

161

Piston

1

366

Spring

1

39

Socket plug

2

162

Shoe

1

368

Steel ball

1

40

Hex. head bolt

3

167

Pivot

2

375

Hex. socket plug

4

41

Steel ball

1

171

Parallel pin

2

377

Orifice

2

42

Parallel pin

2

190

Spring

1

379

Filter

1

43

O-ring

2

201

Valve seat

2

380

Orifice

1

44

O-ring

1

202

Valve

2

382

Plug

3

45

Ring

1

203

Sleeve

2

383

Plug

1

47

Hex. socket set screw

2

204

Coller

2

392

O-ring

1

50

Retainning ring

1

205

Plug

2

399

Name plate

1

51

Hex. head bolt

4

206

Spring

2

102

Shaft

1

207

O-ring

2

ASM-17-21-002

Issued 08-2008

Copyright ©

6003

Section 6003 REMOVAL AND INSTALLATION OF THE SWING MOTOR AND SWING REDUCTION GEAR

CNH

Lep SM75SR6003-0EN


Copyright © 6003-2

SWING UNIT Air bleeder

9

10

X7

8 11 272.6 to 317.7 Nm

1

7

X22

2

1. 2. 3. 4. 5. 6.

Turn table bearing assembly (1) High strength bolt M16x80 (22) High strength bolt M16x90 (24) Cover plate (1) Cork packing (1) Bolt M10x20 (2)

ASM-17-11-002

7. 8. 9. 10. 11. 12.

252.0 to 283.4 Nm

KAC0178Z-C05

Liquid packing Loctite Swing motor (1) Knock pin (1) High strength bolt M16x50 (7) Spl bolt M16x80 (2)

Issued 08-2008

Copyright © 6003-3 Notes Coat the thread with loctite 262 after removing any oil film.

3

(S mark position)

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

X24

Inner race soft zone

12

252.0 to 283.4 Nm

8

252.0 to 283.4 Nm

Outer race soft zone (Slot position)

1

grease nipple

12 252.0 to 283.4 Nm

X2

6

4

5 KACO178Z-C05

ASM-17-11-002

Issued 08-2008

Copyright © 6003-4 Notes Use hydraulic of motor drain for lubrication of the gear box. Feelthe hydrauric motor case with working fluid before strating. (The hydraulic motor and the reduction gear are not filled with the hydraulic oil. when it is delivered.) Suitable piping is recommended, such as the motor and reduction gear are filled with the hydraulic oil always.

Air bleeder

Install a filter in drain line: Recommended filtration rate: 0.074 mm (200 mesh). 1.

Swing motor

2.

Reduction gear assembly

㪈

㪉

-#%:#

ASM-17-11-002

Issued 08-2008

8001

Copyright ©

Section 8001 SPECIFICATIONS, TROUBLESHOOTING, INSPECTIONS AND HYDRAULIC PRESSURE SETTING

CNH



Copyright © 8001-2

TABLE OF CONTENTS

!

WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message which follows. Your safety depends on it.

SPECIFICATIONS .................................................................................................................................................... 3 SPECIAL TOOLS ...................................................................................................................................................... 3 Tester .................................................................................................................................................................... 3 IDENTIFICATION OF HYDRAULIC COMPONENTS ............................................................................................... 5 Pump..................................................................................................................................................................... 5 Control valve (CX75SR MONO BOOM)................................................................................................................ 6 Control valve (CX80)............................................................................................................................................. 8 Control valve (CX75SR OFFSET BOOM)........................................................................................................... 10 MEASURING PRESSURE...................................................................................................................................... 12 PRESSURE ADJUSTMENT ................................................................................................................................... 18 BLEEDING AIR ....................................................................................................................................................... 21 FLOW CURVE ........................................................................................................................................................ 22


Issued 03-08

Copyright © 8001-3

SPECIFICATIONS See section 1002.

SPECIAL TOOLS Tester 1

2

3

4

CD01B005

CP96E001

1. TEST KIT E5444449 FOR MULTI-HANDY 2051

2. FEMALE COUPLING JOINT E47894 (1) PRESSURE TEST POINT 14X1.5 A3237549 (2) MALE COUPLING JOINT WITH UNION (3) AND PLUGS (4) CONTAINED IN THE SUITCASE CAS 30038

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


CD98M009

3. 600 LITRE FLOWMETER, ORDER THE FOLLOWING: ONE FLOWMETER RE3 Z5344486 TWO PLATES (M45X2) D4323359 TWO FLANGES (Ø 24) B8230183 FOUR HALF FLANGES D4024267 EIGHT SCREWS (12 X 75) Z1232983

Issued 03-08

Copyright © 8001-4

CS99B532

4. SET OF UNIONS FOR PRESSURE TEST AND HYDRAULIC FLOW CAS 30038.

CD99C002

5. SET OF HIGH PRESSURE HYDRAULIC HOSES CAS XXXXX (INCLUDING TWO HIGH PRESSURE HOSES).


Issued 03-08

Copyright © 8001-5

IDENTIFICATION OF HYDRAULIC COMPONENTS Pump MUFFLER BRACKET R2

R1

A2 G2 A1 G1

PPG

S

A3 P3G PP AO14001-001

Port

Description

Location

S

Inlet port

SAE 2

A1, A2

Delivery port

G3/4

A3

Delivery port

G1/2

PP

Pilot port

G3/8

PPG

Gauge port (pilot)

G1/4 (plug)

P3G

Gauge port (3rd pump)

G1/4 (plug)

R1

Drain port

G1/2 (plug)

R2

Air bleeding port

M10 x 1.0 (plug)

G1, G2

Gauge port

G1/4 (plug)


Issued 03-08

Copyright © 8001-6

Control valve (CX75SR MONO BOOM) PR5

B8

T2

B6

B7

P3 P2

BR2 A6

AR2 A7

pcc T4

pa7

dr2

TRAVEL

STRAIGHT TRAVEL

BUCKET

BOOM 1

pc2

ARM 2

BLADE

A8

DR1

pa6

T3

pa8

pa2

pa9

pa1

T1

PP

TRAVEL

BACKUP

SWING

A5

BOOM 2

pa4 pa3

ARM 1

pa5

A1 PT

A2

A3

P1

B1

T5

B2

B5

pb5

B3

pb9 Lep SC75SRCX80-8001-1EN

pb4 pb3

pb8 pb7

pb2 pb1

pb6

Issued 03-08

Copyright © 8001-7 Port

Description

Port

Description

A1

Travel line (backward left)

pb1

Travel (forward left) Pilot Line

A2

Backup Line

pb2

Backup Pilot Line

A3

Swing-right Line

pb3

Swing-left Pilot Line

A5

Arm-out Line

pb4

Boom-down 2-speed Pilot Line

A6

Travel Line (backward right)

pb5

Arm-in Pilot Line

A7

Bucket-close Line

pb6

Travel (forward right) Pilot Line

A8

Boom-up Line

pb7

Bucket-open Pilot Line

B1

Travel-line (forward left)

pb8

Boom-down Pilot Line

B2

Backup Line

pb9

Arm-in 2-speed Pilot Line

B3

Swing-left Line

pc2

Load Holding at Boom

B5

Arm-in Line

T1, T2, T3, T4 Return Line

B6

Travel Line (forward right)

T5

Bypass Filter

B7

Bucket-open Line

dr2

Pilot drain

B8

Boom-down Line

pcc

Backup Confluence Pilot Line

DR1

Drain

AR2

Blade-up line

P1, P2, PR5, PP

Pressure Line

BR2

Blade-down line

P3, P4

Backup Confluence Line

pra2

Blade-up pilot line

PA

Attachment Signal Pressure Measurement

prb2

Blade-down pilot line

PT

Travel Signal Pressure Measurement

pa1

Travel (backward left) Pilot Line

pa2

Backup Pilot Line

pa3

Swing-right Pilot Line

pa4

Boom-up 2-speed Pilot Line

pa5

Arm-out Pilot Line

pa6

Travel (backward right) Pilot Line

pa7

Bucket-close Pilot Line

pa8

Boom-up Pilot Line

pa9

Arm-out 2-speed Pilot Line


Issued 03-08

Copyright © 8001-8

Control valve (CX80) B8

T2

BR1

BR2 PR5

B6

B7

P3 P2

BR3 A6

AR3 A7

pcc

T6

AR2

TRAVEL

TRAVEL

dr2

pa8

STRAIGHT

pa7

BUCKET

BOOM 1

pc2

ARM 2

A8

pra1

AR1

BOOM SWING

pra2

BLADE

pra3

BACKUP 2

T4

DR1 T3

pa9

pa6

pa5

pa1

A5

TRAVEL

BACKUP 1

SWING

ARM 1

pa3

BOOM 2

UP

pa4

MOUNTING DIRECTION

pa2

PP A3 PT

PA A1

T1 A2 P1

B5

P4 T5 B4

B3

B2

B1

pb5 pb4 pb3 pb2 pb1 prb3

prb2 prb1

pb9 pb8 pb7 pb6


Issued 03-08


Description

Port

Description

A1


pb1


A2

Backup Line

pb2

Backup Pilot Line

A3

Swing-right Line

pb3


A5

Arm-out Line

pb4


A6


pb5

Arm-in Pilot Line

A7

Bucket-close Line

pb6

Travel (forward right) Pilot Line

A8

Boom-up Line

pb7


B1

Travel-line (forward left)

pb8


B2

Backup (1) Line

pb9


B3

Swing-left Line

pc2


B5

Arm-in Line


B6


T5

Bypass Filter

B7

Bucket-open Line

dr2

Pilot drain

B8

Boom-down Line

pcc


DR1

Drain

AR2

Blade-up line

P1, P2, PP

Pressure Line

BR2

Blade-down line

P3, P4


pra2

Blade-up pilot line

PA


prb2


PT


pra1

Swing-right pilot line

pa1


prb1

Swing-left pilot line

pa2

Backup Pilot Line

AR1

Swing-right line

pa3


BR1

Swing-left line

pa4


pra3, prb3

Buckup (2) pilot line

pa5

Arm-out Pilot Line

AR3, BR3

Buckup (2) line

pa6


PR5

Blade pressure line

pa7


B4

Plug

pa8

Boom-up Pilot Line

pa9



Issued 03-08


Control valve (CX75SR OFFSET BOOM) PR5

B8

T2

P3

B6

B7

P2 BR2 A6

AR2 A7

pcc T4

pa7

STRAIGHT TRAVEL

TRAVEL

BUCKET

BOOM 1

BLADE

pc2

ARM 2

A8

dr2

DR1

pa6

T3

pa8

pa2

pa9

pa1

T1

PP

TRAVEL

BACKUP

SWING

A5

ARM 1

pa4 pa3

BOOM 2

pa5

A1 PT

A2

A3

P1

B1

T5

B2

B5

pb5

B3

pb4

pb3

pb2 pb1

pb9


pb8 pb7

pb6

Issued 03-08


Description

Port

Description

A1


pb1


A2

Backup left Line

pb2

Offset right Pilot Line

A3

Swing-right Line

pb3


A5

Arm-out Line

pb4


A6


pb5

Arm-in Pilot Line

A7

Bucket-close Line

pb6

Travel (forward line) Pilot Line

A8

Boom-up Line

pb7


B1

Travel line (forward left)

pb8


B2

Offset right Line

pb9


B3

Swing-left Line

pc2


B5

Arm-in Line


B6


T5

Bypass Filter

B7

Bucket-open Line

dr2

Pilot drain

B8

Boom-down Line

pcc


DR1

Drain

AR2

Blade-up line

P1, P2, PR5, PP

Pressure Line

BR2

Blade-down line

P3


pra2

Blade-up pilot line

PA


prb2


PT


pa1


pa2

Offset left Pilot Line

pa3


pa4


pa5

Arm-out Pilot Line

pa6


pa7


pa8

Boom-up Pilot Line

pa9



Issued 03-08


MEASURING PRESSURE 1) Basic Conditions Oil temperature

45 - 55 °C {113 - 131°F°}

Engine revolutions at no load

2200 rpm {2200 min-1}

2) Pressure Settings Relief valve Individual pressure settings

Actual readings measured on machines (reference)

Method of measurement

29.4 MPa at 44 L/min {4264 psi at 11.6 gpm}

29.7 MPa {4307 psi}

Arm relief

Up


33.5 MPa {4858 psi}

Fasten main relief 180° + Boom-up relief

Down


33.2 MPa {4815 psi}

Fasten main relief 180° + Boom-down relief

Out


32.7 MPa {4742 psi}

Fasten main relief 180° + Arm-out relief

In


33.0 MPa {4786 psi}

Fasten main relief 180° + Arm-in relief

Open


33.1 MPa {4800 psi}

Fasten main relief 180° + Bucket-open relief

Close


33.1 MPa {4800 psi}

Fasten main relief 180° + Bucket-closed relief

Right

22.6 MPa at 57.5 L/min {3277 psi at 15.2 gpm}

25.0 MPa {3625 psi}

Swing relief

Left

22.6 MPa at 57.5 L/min {3277 psi at 15.2 gpm}

25.0 MPa {3625 psi}

Swing relief

Right


33.7 MPa {4888 psi}

Fasten main relief 180° + Boom swing-right relief

Left


32.9 MPa {4772 psi}

Fasten main relief 180° + Boom swing-left relief


23.3 MPa {3379 psi}

Blade-up relief

Up


26.5 MPa {3843 psi}

Fasten blade main relief 180° + Blade-up relief

Down


26.5 MPa {3843 psi}

Fasten blade main relief 180° + Blade-down relief

4.2 MPa {609 psi}

3.8 MPa {551 psi}

Lever neutral

Main relief pressure

Boom overload relief

Arm overload relief

Bucket overload relief

Swing relief

Boom Swing port relief (CX80)

Main

Blade

Overload relief

Pilot relief


Issued 03-08


3) Ports for Measuring Pressure 1] Main pump MAIN PUMP ENGINE BLADE PUMP

PILOT PUMP

G2 PRESSURE DETECTION PORT G1/4 A2 RIGHT TRAVEL SIDE DELIVERY PORT FRONT SIDE OF BODY

G1 PRESSURE DETECTION PORT G1/4 A1 LEFT TRAVEL SIDE DELIVERY PORT PG3 BLADE PUMP PRESSURE DETECTION PORT G1/4

2] Pilot line

PRG


Issued 03-08


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

Temperature gauge

2] Positioning the machine •Position the machine on solid level ground. Lower the boom so the arm end touches the ground with the bucket cylinder out at stroke end and the arm cylinder out at stroke end. The blade should also be lowered to touch the ground.


Issued 03-08


3] Relieving pressure in circuit •Turn the starter switch off and confirm that the engine has stopped. Turn the key on again. NOTE: Do not start the engine.

•Operate each lever 10 times or more and check that the attachments no longer move. Then turn off the starter switch.

4] Relieving pressure in hydraulic oil tank •Press the air breather button located on the hydraulic oil tank to release the pressure in the tank.

5] Attaching the pressure gauge See section 3 on the previous page for the port positions for measuring. Measuring actuator

Port

Pressure gauge

Port size

Tool

Main, Left travel, Offsett,Swing, Arm

G1

49.1 MPa {7221 psi}

G1/4

Hexagonal bar wrench 6 mm

Main, Right travel, Bucket, Boom

G2

49.1 MPa {7221 psi}

G1/4


Pilot

P2

9.8 MPa {1421 psi}

G1/4

Spanner 17 mm

P3G

49.1 MPa {7221 psi}

G1/4


Blade

6] Checking oil temperature Check hydraulic oil temperatures using a temperature gauge. Oil temperature

45 - 55 °C (113 - 131 °F)

If the oil temperature is low, follow the instructions for warm-up in the Operator’s Manual to increase the temperature. The preparation is now complete.


Issued 03-08


5) Measuring Pressure 1] Main relief pressure Lever operation

Arm-in relief

Pressure gauge to be used

50 MPa {7250 psi}

Pressure setting

29.4 ± 1.0 MPa {4264 ± 145 psi}

2] Swing relief pressure Lever operation

Swing relief


50 MPa {7250 psi}

Pressure setting

24.6 ± 1.0 MPa {3567 ± 145 psi}

Attach the pressure gauge to the G1 side of the pressure detection port on the main pump. When measuring the pressure for swing, first activate the mechanical brake by disconnecting the connector on the swing pressure switch located on the lower left of the cab. The swing pressure switch will be revealed after removing the side cover located on the lower left of the cab. See the figure below. CAUTION Before positioning the swing lever in place for the first time, the engine revolutions should be reduced to approximately 1100 min-1{1100 rpm}. When the swing is confirmed to be no longer moving, increase the engine revolutions to the maximum. Disconnecting the hose to the swing motor’s parking release port PB or inserting the connector of the solenoid valve for switching for high speed into swing brake solenoid to change the speed to high mode would also work for measuring pressure along with disconnecting the connector. (At this point, leave the connector for the swing brake solenoid disconnected.)

HIGH SPEED TRAVEL GATE LOCK

FRONT SIDE OF BODY SWING BRAKE

BOTTOM OF CAB


SWING PRESSURE SWITCH

Issued 03-08


3] Pilot relief pressure Lever operation

Neutral


10 MPa {1450 psi}

Pressure setting

3.9 ± 0.2 MPa {540 ± 29 psi}

4] Blade relief pressure Main relief pressure for blade Lever operation

Blade up


50 MPa {7250 psi}

Pressure setting

23.0 ± 1.0 MPa {3335 ± 145 psi}

Overload relief pressure for blade Lever operation

Blade up/down


50 MPa {7250 psi}

Pressure setting

26.4 ± 1.0 MPa {3829 ± 145 psi}

Overload relief pressure for boom swing (CX80) Lever operation

Boom swing-right/left


49.1 MPa {7121 psi}

Actual pressure setting (Right)

33.7 ± 1.0 MPa {4888 ± 145 psi}

Actual pressure setting (Left)

32.9 ± 1.0 MPa {4772 ± 145 psi}

When measuring the overload relief pressure, fasten the main relief valve of the blade 180° to temporarily adjust it. 5] Other overload relief pressures Lever operation

Boom up

Boom down

Actual pressure reading

33.5 ± 1.0 MPa {4860 ±145 psi}

Port for detection

G2

Arm out

Arm in

33.4 ± 1.0 MPa {4844 ±145 psi} G1

Bucket open

Bucket closed

32.8 ± 1.0 MPa {4760 ±145 psi} G2

Offset right (CX75SR) 32.9 ± 1.0 MPa {4770 ±145 psi}

Offset left (CX75SR) 33.7 ± 1.0 MPa {4890 ±145 psi} G1

Temporary adjustments are required because the overload relief pressures of the attachments are set higher than those for the main relief.


Issued 03-08


PRESSURE ADJUSTMENT 1) Pressure Adjusting Points 1] Control valve (CX75SR)

OFFSET LEFT

OFFSET RIGHT BLADE UP

BLADE DOWN

ARM 1 OUT ARM 2

ARM 1 IN

B00M 2 UP

BOOM 2 DOWN SWING RIGHT

SWING LEFT

OPTION OUT

OPTION IN

TRAVEL BACKWARD LEFT

TRAVEL FOWARD LEFT

FRONT SIDE OF BODY VIEWED FROM THE EXTERNAL SIDE OF BODY

BOOM 1 DOWN BUCKET OPEN TRAVEL FORWARD RIGHT

BOOM 1 UP BUCKET CLOSED TRAVEL BACKWARD RIGHT

FRONT SIDE OF BODY VIEWED FROM THE INTERNAL SIDE BODY

Tool needed Location Lock nut 1

Main

2

Boom up

3

Boom down

4

Arm out

5

Arm in

6

Bucket open

7

Bucket closed

8

Option in

Adjustment screw

Pressure setting

29.4 MPa {4260 psi}

Pressure per one turn of adjustment screw 17.8 MPa {2580 psi}

33.5 MPa {4860 psi}

33.4 MPa {4844 psi}

17 mm

Hexagonal wrench 6 mm

32.8 MPa {4760 psi} 21.2 MPa {3070 psi} 31.9 MPa {4630 psi}

9

Option out

10

Blade, offset main

11

Blade up

12

Blade down

13

Offset right

32.9 MPa {4770 psi}

14

Offset left

33.7 MPa {4890 psi}

23.0 MPa {3335 psi} 26.4 MPa {3830 psi}


Issued 03-08


2] Control valve (CX80)

OPTION (2) IN BLADE UP

BOOM SWING RIGHT

ARM 1 IN

ARM 1 OUT

BOOM 2 DOWN

B00M 2 UP

SWING LEFT

SWING RIGHT

OPTION IN

OPTION (1) OUT

TRAVEL FOWARD LEFT

TRAVEL BACKWARD LEFT

FRONT SIDE OF BODY VIEWED FROM THE EXTERNAL SIDE OF BODY

OPTION (2) OUT BLADE DOWN

BOOM SWING LEFT

ARM 2 BOOM 1 UP BUCKET CLOSED TRAVEL BACKWARD RIGHT

BOOM 1 DOWN BUCKET OPEN TRAVEL FORWARD RIGHT

FRONT SIDE OF BODY VIEWED FROM THE INTERNAL SIDE BODY

Tool needed Location Lock nut

Adjustment screw

Pressure setting

1

Main

29.7 MPa {4308 psi}

2

Boom up

33.5 MPa {4859 psi}

3

Boom down

33.2 MPa {4815 psi}

4

Arm out

32.7 MPa {4743 psi}

5

Arm in

33.0 MPa {4786 psi}

6

Bucket open

33.1 MPa {4801 psi}

7

Bucket closed

33.1 MPa {4801 psi}

8

Option (1) in 17 mm


9

Option (1) out

10

Boom swing-right

33.7 MPa {4888 psi}

11

Boom swing-left

32.9 MPa {4772 psi}

12

Blade main

23.3 MPa {3379 psi}

13

Blade up

26.5 MPa {3844 psi}

14

Blade down

26.5 MPa {3844 psi}

15

Option (2) in

16

Option (2) out


Pressure per one turn of adjustment screw 17.8 MPa {2582 psi}

21.2 MPa {3070 psi}

Issued 03-08


3] Hydraulic pump

4] Swing motor

Tool needed Name Lock nut

Adjustment screw

13

Pilot

24 mm

14 mm

14

Swing Motor

17 mm



Pressure setting

Pressure per one turn of adjustment screw

3.9 MPa {570 psi}

0.6 MPa {87 psi}

24.6 MPa {3570 psi}

9.7 MPa {1410 psi}

Issued 03-08


BLEEDING AIR MAIN PUMP AIR BLEEDING VALVE BLADE PUMP PILOT PUMP DIA Ø 6.3 mm (0.24 in)

HEX. WAF 10 mm (0.39 in)

RUBBER CAP

SEAT FACE FRONT SIDE OF BODY

Start the engine and keep it at idle. Remove the rubber cap on the air bleeder. Loosen the air bleeding valve gradually to bleed air.


Issued 03-08


FLOW CURVE

Torque: Nm

ΣP = P1 + P2

Shift pressure P3 MPa

Leakage flow line

Flow: Q1, Q2 L/min

AQ08002-001


Issued 03-08

8002

Copyright ©

Section 8002 REMOVAL AND INSTALLATION OF THE HYDRAULIC RESERVOIR

CNH

Lep SM75SR8002-0EN


Copyright © 8002-2

TABLE OF CONTENTS HYDRAULIC RESERVOIR ...................................................................................................................................... 3

Lep SM75SR8002-0EN

Issued 08-2008

Copyright © 8002-3

HYDRAULIC RESERVOIR x4x4 2 3 2.94 to 4.90 Nm

x4 6 1

6

4 9 5 9 See detail A

10

7 8 15

16 17

14

X4

9

Lep AST-15-11-003

X4

11 12 13 68.6 to 78.5Nm

KAJ11230-D00

Issued 08-2008

Copyright © 8002-4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Air breather Hex bolt soc HD M6 x 16 Spring washer Sems bolt M10 x 30 Hydraulic reservoir Sems bolt M10 x 20 Plate shim (T=2) Plate shim (T=0.8) Plug G3/4 Cushion seal High strength bolt M12 x 45 High strength washer Bond #262 Strainer Compression spring Relief valve Return filter Oil gauge level

18 12.75Nm

A

9

9

KAJ11230-D00

Lep AST-15-11-003

Issued 08-2008

Copyright ©

8003

Section 8003 REMOVAL AND INSTALLATION OF THE MAIN HYDRAULIC PUMP

CNH

Lep SM75SR8003-0EN


Copyright © 8003-2

HYDRAULIC PUMP X4 X4

1 2 3 108.9 to 126.5 Nm R2

R1 A2

4

G2

10

A

A1 X9

G1

1 5 62.8 to 72.6 Nm

8 9

6 7

A PPG S 130 to 150 Nm

8 9

100 to 120 Nm A3 P3G PP 130 to 150 Nm

A 1. 2. 3. 4. 5.

A

KAJ11370-C00

6. 7. 8. 9. 10.

Bond 262 (-) Spring washer 12 (4) Hex bolt soc hd M12 x 30 (4) Mount flange (1) Bolt M10 x 30 (9) Mark

Name

Bushing (3) Cplg plug (3) Hydraulic pump (1) Hydraulic pump (for blade) (1) Pump coupling (1)

Bore

Mark

S

Suction port

SAE2 1/2

P3G

A1, A2

Delivery port

G3/4

A3

Delivery port

PP

Pilot port

PPG

Gauge port (pilot)

Name

Bore

Gauge port (gear)

G1/4 Plug

R1

Drain port

G1/2 Plug

G1/2

R

Air-bleeding port

M10 x 1.0

G3/8

G1, G2

Gauge port

G1/4 Plug

G1/4 Plug

-

1. Loctite 262 or equivalent should be applied on the thread of the bolts after removing the oil film. All hexagon socket head cap screws for the drive plate coupling have been already done by vender.

-

-

3. The pump shaft and flange surfaces should be cleaned. (for removing anti-rust material)

2. After assembled the machine or long term storage of the machine. At first loose the air-bleeding plug R2 and fill inside of the pump with the hydraulic oil before starting the engine.

ASM-17-11-002

Issued 08-2008

Copyright ©

Section

REMOVAL AND INSTALLATION OF THE MAIN HYDRAULIC CONTROL VALVE

CX80 TIER 3

CNH

Lep SM80-8004-0EN


8004

8004

Copyright © 8004-2

CONTROL VALVE pp

T3

DR1 1 p pa6

p pa1 pa2 p pa p dr p pa p pa

p pa3 p pa4 p pra1 p pa5 pra2 p p pra3

X4

1 4

A8 A7 A6

T4 pc2

pcc AR1 T6 AR2 AR3

T5

X4

2 3 4

5

6

7 A5 A3 A2 A1 PT PA

R3 2

P2 2

P1

B5 5 B4 4 B3 3 B2 2

P3 B6 B7 B8 T2 prb3 p prb2

B1

pb5 rb1 p p pb4 p pb3 p pb2 p pb1

KAJ11680-D00

1. 2. 3. 4.

Sems bolt M12 x 30 (4) High strength M12 x 40 (4) High strength washer 12 (4) Bond 262 (-)

Main line P1, P2 T1, T2 A1 B1 A2 B2 A3 B3 B4 A5 B5 A6 B6 A7

Pilot port pa1 pb1 pa2 pb2 pa3 pb3 pa5, pa9 pb5, pb9 pa6 pb6 pa7

B7

pb7

ASM-19-04-001

5. 6. 7. 8. Line name

Pressure line Low pressure line Traction line left backward Traction line left forward Option 1 Option 1 Swing line right Swing line left Plug (boom 2) Arm line out Arm line in Traction line right backward Traction line right forward Bucket line close Bucket line open

Plug (1) Protection cap (1) Plate (1) Control valve (1)

Main line A8 B8 T3 AR1 BR1 AR2 BR2 AR3 BR3 PR5 T5 P3, T4 -

Pilot port pa8, pa4 pb8, pc2 pra1 prb1 pra2 prb2 pra3 prb3 PP PT, PA DR1, pcc, dr2, pb4

Line name Boom line up Boom line down Swing line Swing right Swing left Blade line up Blade line down Option 2 Option 2 Blade line pressure Plug Plug Pilot pressure line Pressure detection Drain line

Issued 08-2008

Copyright ©

Section

REMOVAL AND INSTALLATION OF THE ATTACHMENT CYLINDERS

CNH

Lep SM75SR8005-0EN


8005

8005

Copyright © 8005-2

TABLE OF CONTENTS ATTACHMENT CYLINDERS................................................................................................................................... 3 BUCKET CYLINDER ................................................................................................................................................ 3 Removal ............................................................................................................................................................ 3 Installation ......................................................................................................................................................... 5 DIPPER CYLINDER ................................................................................................................................................. 7 Removal ............................................................................................................................................................ 7 Installation ......................................................................................................................................................... 9 BOOM CYLINDER ................................................................................................................................................. 11 Removal .......................................................................................................................................................... 11 Installation ....................................................................................................................................................... 13 BOOM SWING CYLINDER (CX80 ONLY) ................................................................................................................. 16 Removal .......................................................................................................................................................... 16 Installation ....................................................................................................................................................... 17

Lep SM75SR8005-0EN

Issued 08-2008

Copyright © 8005-3

ATTACHMENT CYLINDERS 1 Bucket cylinder 1 Removal 1) Lower the attachment to the ground.

800-5-03-00-21A

2) Put a block between the bucket cylinder and the dipper.

MQ12001-001-003

3) Stop the engine and release pressure in the hydraulic circuit. NOTE: Refer to the procedures for bleeding the hydraulic pressure in Operator’s manual. When releasing pressure from the tank, stop the engine and press the button to completely release the internal pressure. The hydraulic oil may be hot, so be careful not to get burned.

800-5-03-00-20C

4) Remove the nuts and bolt.

800-5-03-00-20D

MSM-17-12-001

Issued 08-2008

Copyright © 8005-4 5) Drive out the pin, using a steel bar and hammer.

800-5-03-00-20E

6) Fasten a wire to prevent the cylinder rod from extending.

800-5-03-00-20F

7) Remove the hoses. Install bull plugs or caps.

MQ12001-002

8) Lift the bucket cylinder, using a sling.

MQ12001-003

MSM-17-12-001

Issued 08-2008

Copyright © 8005-5 9) Remove the nuts and bolt. Drive out the pin, using a steel bar and hammer. 10)Remove the bucket cylinder.

MQ12001-004

2 Installation 1) Lift the bucket cylinder and position it so that it is aligned for installation in the dipper.

MQ12001-005

2) Install the pin and fasten it with a bolt and nuts.

MQ12001-006

3) Connect the hoses to the bucket cylinder.

MQ12001-007

MSM-17-12-001

Issued 08-2008

Copyright © 8005-6 4) Position the cylinder head so that it is aligned for installation in the link.

MQ12001-008

5) Install the pin and fasten it with a bolt and nuts. NOTE: Cycle the cylinder to bleed air from the cylinder. After leading air, check for oil leakage.

MQ12001-009

MSM-17-12-001

Issued 08-2008

Copyright © 8005-7

2 Dipper cylinder 1 Removal 1) Lower the attachment to the ground.

800-5-03-00-21A

2) Put a block between the dipper cylinder and the boom.

700-5-03-00-22R

3) Stop the engine and release pressure in the hydraulic circuit. NOTE: Refer to the procedures for bleeding the hydraulic pressure in Operator’s Manual. When releasing pressure from the tank, stop the engine and press the button to completely release the internal pressure. The hydraulic oil may be hot, so be careful not to get burned.

800-5-03-00-20C

4) Remove the nuts and bolt.

MQ12001-010

MSM-17-12-001

Issued 08-2008

Copyright © 8005-8 5) Drive out the pin, using a steel bar and hammer.

MQ12001-011

6) Fasten a wire to prevent the cylinder rod from extending.

800-5-03-00-20F


MQ12001-012

8) Remove the grease hose.

MQ12001-013

MSM-17-12-001

Issued 08-2008

Copyright © 8005-9 9) Lift the dipper cylinder, using a sling.

700-5-03-00-22Y

10)Remove the nuts and bolt. Drive out the pin, using a steel bar and hammer. 11)Remove the dipper cylinder.

MQ12001-014

2 Installation 1) Lift the dipper cylinder and position it so that it is aligned for installation in the boom.

700-5-03-00-22AA


MQ12001-015

MSM-17-12-001

Issued 08-2008

Copyright © 8005-10 3) Install the grease hose to the dipper cylinder.

MQ12001-016

4) Connect the hoses to the dipper cylinder.

MQ12001-017

5) Position the cylinder head so that it is aligned for installation in the arm.

MQ12001-018

6) Install the pin and fasten it with a bolt and spacer. When putting in a pin, it unites with the circle boss of a dipper. NOTE: Cycle the cylinder to bleed air from the cylinder. After bleeding air, check for oil leakage.

MQ12001-019

MSM-17-12-001

Issued 08-2008


3 Boom cylinder 1 Removal 1) Lower the attachment to the ground.

800-5-03-00-21A

2) Remove the grease hose.

700-5-03-00-22AH

3) Attach a sling to the boom cylinder.

700-5-03-00-22AI

4) Remove the nuts and bolt to remove the collar. 5) Pull out the pin, using a steel bar and hammer.

000-5-03-00-20AC

MSM-17-12-001

Issued 08-2008

Copyright © 8005-12 6) Lower the cylinder and place on a stand.

700-5-03-00-22AK

7) Attach a wire to prevent the cylinder rod from extending.

MQ12001-020

8) Stop the engine and release pressure in the hydraulic circuit. NOTE: Refer to the procedures for bleeding the hydraulic pressure in Operator’s Manual. When releasing pressure from the tank, stop the engine and press the button to completely release the internal pressure. The hydraulic oil may be hot, so be careful not to get burned.

800-5-03-00-20C


MQ12001-021

MSM-17-12-001

Issued 08-2008

Copyright © 8005-13 10)Remove the nuts and bolt and drive out the pin, with a steel bar and hammer.

MQ12001-022

11)Remove the boom cylinder.

MQ12001-023

2 Installation 1) Lift the boom cylinder and position it so that it is aligned for installation in the frame.

MQ12001-024


MQ12001-025

MSM-17-12-001

Issued 08-2008

Copyright © 8005-14 3) Connect the hoses to the boom cylinder.

MQ12001-026

4) Position the cylinder so that the head is aligned for installation in the boom.

700-5-03-00-22AS

5) Install the pin with a steel bar and hammer.

700-5-03-00-22AM

6) Attach the collar and install the bolt and nuts.

MQ12001-027

MSM-17-12-001

Issued 08-2008

Copyright © 8005-15 7) Install the grease hose. NOTE: Cycle the cylinder to bleed air from the cylinder. After bleeding air, check for oil leakage.

700-5-03-00-22AU

MSM-17-12-001

Issued 08-2008


4 Boom swing cylinder (CX80 only) 1 Removal

4 6

1 5 2 3

7 9 8 AS05001-043

[1] Use wire to lift the boom swing cylinder (1). [2] Use a wrench to remove the bolt (5) on the cylinder head (piston rod side) (2). [3] Use a steel rod and hammer to remove the pin (3). WARNING: When removing the pin, be careful not to let it fall or get caught. [4] [5] [6] [7] [8] [9]

Secure the piston rod (2) with wire so that it will not fall out. Remove the hose (4) and cover the hose with either a plug or cap. Use a wrench to remove the bolt (8) on cylinder bottom (cylinder tube side) (6) and washer (9). Use a steel rod and hammer to remove the pin (7). Lift the boom swing cylinder (1) and remove it. Place the boom swing cylinder (1) on crossties.

MSM-17-12-001

Issued 08-2008

Copyright © 8005-17 2 Installation To install, perform the reverse of the removal procedure. [1] Use wire to lift the boom swing cylinder (1), and align the cylinder bottom (cylinder tube side) (6) with the installation position. [2] Insert the pin (7) and secure it with the bolt (8) and washer (9). [3] Connect the boom swing cylinder (1) to the hose (4). • Do not pull out the piston rod (2) before connecting the hose. This can cause hydraulic oil to fly out from the line. [4] [5] [6] [7] • •

Align the cylinder head (piston rod side) with the installation position. Use a steel rod and hammer to insert the pin (3). Secure the bolt (5) with the pin (3). Remove wire, etc. Bleed off air and check that there is no oil leaking. As the final step, always grease up each pin.

MSM-17-12-001

Issued 08-2008


NOTES .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... MSM-17-12-001

Issued 08-2008

Copyright ©

Section 8006

8006

REMOVAL AND INSTALLATION OF THE HYDRAULIC SWIVEL

CNH

Lep SM75SR8006-0EN


Copyright © 8006-2

TABLE OF CONTENTS ROTATING JOINT ................................................................................................................................................... 3 Removal ............................................................................................................................................................ 4 Installation ......................................................................................................................................................... 5

Lep SM75SR8006-0EN

Issued 08-2008

Copyright © 8006-3

ROTATING JOINT

AQ10002-029

1. Bolt 2. Lock bar 3. Rotating joint assembly

ASM-17-10-002

Issued 08-2008

Copyright © 8006-4 1 Removal 1) Jack up the body. 2) Stop engine and release pressure in the hydraulic circuits. 3) Place protection blocks under the lower frame and secure them.

AQ10002-030A

4) Remove the under cover.

AQ10002-030B

5) Attach marking tags to the rotating joint hoses to tell them apart when they are reconnected. 6) Remove the hoses and put blank plugs or caps on them to keep out dust.

AQ10002-030C

7) Remone the lock bar mounting bolts (1). 8) Remove the lock bar (2). 9) Remove the rotating joint mounting bolts (3). 10) Lift out the rotating joint.

AQ10002-030

ASM-17-10-002

Issued 08-2008

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

ASM-17-10-002

Issued 08-2008

Copyright © 8006-6

NOTES .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... ASM-17-10-002

Issued 08-2008

Copyright ©

Section 8007

8007

REMOVAL AND INSTALLATION OF THE PILOT FUNCTION BLOCKS

CNH

Lep SM75SR8007-0EN


Copyright © 8007-2

TABLE OF CONTENTS REMOTE CONTROL VALVE .................................................................................................................................. 3

Lep SM75SR8007-0EN

Issued 08-2008

Copyright © 8007-3

REMOTE CONTROL VALVE 41.1 ± 2.9 Nm 17 18

54 59 63 67

41.1 ± 2.9 Nm

19 61

X4

X4 X4 X4

20

23 60 64 68

17 18

22 24

19 61

X4 4 X4 4 X4

20 21 22

5

6 70.6 ~ 86.2 Nm

25 46 26

12 13 14 X44 33

5

31 32 X44 X4 28 29 30

6 70.6 ~ 86.2 Nm

27 X4

2

7

66 3 X4

2 1 4

56

70.6 ~ 86.2 Nm 5 7

8 10 9 51 X10

11

X2 2 X2

X

13 14

2 70.6 ~ 86.2 Nm 5

6

15

46

KHJ2287Z-E26A 7

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 17. 18. 19.

Frame console (1) Bolt M10 x 25 (28) Vinyl cap (1) Hand lever(1) Washer (4) U-nut (4) Mount rubber (4) Rubber grommet (2) Floor (1) Floor (1) Bolt M12 x 30 (10) Pedal (2) High strength bolt M10 x 30 (4) High strength washer 10 (6) Bracket right (1) Jam nut M14 (2) Vinyl cap (2) Remote control valve

ASM-17-11-002

20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.

Hex soc hd bolt M6 x 30 (8) Spring washer 6 (8) Plain washer 6 (8) Knob left 2 switch (1) Frame console unit (1) Rubber grommet (1) Rubber grommet (1) Bracket left (1) High strength bolt M8 x 20 (4) Plain washer 8 (4) Bolt M8 x 25 (4) Remote control valve (1) Remote control valve (1) Bolt M10 x 20 (4) Floor mat (SB) Floor mat (BH) Bolt M10 x 16 (3)

Issued 08-2008

Copyright © 8007-4

36 37

X2

36

X2

39

2

X2

40

38

A

2

X2

41 X2

42 17.7 ~ 20.6 Nm

A

34 35 69 70

C B 46

46

B

P - Port

4 - Arm open

3 - Swing left 2 - Arm closed

T - Port 1 - Swing right

57

D

T - Port

58

1 - Bucket closed 4 - Boom up

50 14 45 2 - Boom down

P - Port 3 - Bucket open

C

37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52.

Cover (1) Foot rest left (1) Cover (1) Foot rest right (1) Knob L type (2) High strength nut M12 x 1.25 (2) Hand lever left (1) Hand lever right (1) High strength bolt (2) Cushion seal (2) Cushion seal (2) Cushion seal (1) Cushion seal (1) Safety trim (1) Cover (1) Bolt M10 x 30 (8)

ASM-17-11-002

46

KHJ2287Z-E26

54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69.

Knob right (1) Rubber grommet (1) Cushion seal (1) High strength bolt M6 x 16 (2) Side cover (1) Knob right 4 switch (1) Knob left 4 switch (1) Remote control valve (2) Harness band L= 250 (-) Knob right 2 switch (1) Knob left 2 switch (1) Boot (2) Boot (for short lever) (2) Knob right 4 switch (1) Knob left 4 switch (1) Floor mat (1)

Issued 08-2008

Copyright ©

Section 8010

CNH

Lep SM75SR8010-0EN


8010

DISASSEMBLY AND ASSEMBLY OF THE MAIN HYDRAULIC PUMP

Copyright © 8010-2

TABLE OF CONTENTS HYDRAULIC PUMP................................................................................................................................................. 3 DISASSEMBLING AND ASSEMBLING INSTRUCTIONS .................................................................................................. 3 Tools and jigs needed ....................................................................................................................................... 3 Precautions ....................................................................................................................................................... 3 Disassembly instructions................................................................................................................................... 4 Disassembling main pump .............................................................................................................................. 4 Disassembling the cover section..................................................................................................................... 7 Removing the power adjuster (only if required) .............................................................................................. 8 Removing the pilot relief valve (only if required) ............................................................................................. 9 Assembling instructions .................................................................................................................................... 9 Assembling the cover section ......................................................................................................................... 9 Installing the cylinder..................................................................................................................................... 10 Installing the main pump ............................................................................................................................... 11 Disassembling the gear pump......................................................................................................................... 16 Removing the gear pump (G1)...................................................................................................................... 16 Disassembling the gear pump (G1) .............................................................................................................. 16 Disassembling the gear pump (GSP2).......................................................................................................... 17 Reassembling gear pump ............................................................................................................................... 19 Reassembling the gear pump (GSP2) .......................................................................................................... 19 Assembling the gear pump (G1) ................................................................................................................... 21 STRUCTURE DRAWING ......................................................................................................................................... 25 No. 1 Shaft assembly ...................................................................................................................................... 26 No. 2 Swash plate assembly ........................................................................................................................... 26 No. 3 Rotary group .......................................................................................................................................... 27 No. 4 Cover assembly ..................................................................................................................................... 27 No. 5 Control spring assembly ........................................................................................................................ 28 No. 6 Control piston assembly ........................................................................................................................ 28 No. 7 Gear pump............................................................................................................................................. 29 No. 30 Relief valve assembly .......................................................................................................................... 29

Lep SM75SR8010-0EN

Issued 08-2008

Copyright © 8010-3

HYDRAULIC PUMP 1 Disassembling and assembling instructions 1 Tools and jigs needed Name

Size (nominal)

Quantity

Hexagon wrenches (torque wrench)

4, 5, 6, 8, 12 mm

One of each

Wrenches (torque wrench)

14, 17, 24, 27 mm

One of each

Screwdriver (flathead)

Medium-sized

2

Snap ring pliers

Internal (for snap ring 80)

1

Plastic hammer

Medium-sized

1

Magnet

Bar-shaped: approximate diameter 5 mm

1

Grease

Industrial grease

Cleaning solution

As needed As needed

Adhesive agent

Three bond No. 1305

As needed

Support

1

To be used for standing the pump vertically 2 Precautions [1] Precautions for disassembling 1) Adjusting screws are pre-adjusted according to the specifications. Do not disassemble unless necessary. If disassembled, settings will be altered, adversely affecting the machine. 2) After draining oil from the pump, clean the outside of the pump. Conduct work in a clean area. 3) Use a clean cloth and take sufficient measures to keep foreign substances from entering the pump. 4) Each pump is composed of pre-adjusted parts. Mark each part with a pen or the like so that they can be aligned correctly during reassembly. [2] Precautions for assembling 1) Replace old seals with new ones. 2) Conduct work in a clean area and take sufficient measures to keep foreign substances from entering the pump. 3) Fasten screws with proper tightening torque. 4) Apply grease to all sliding sections.

ASM-17-20-002

Issued 08-2008

Copyright © 8010-4 3 Disassembly instructions 1 Disassembling main pump 1) Remove gear pump. Remove hexagon socket head bolts: (M10 x 25 x2) Hexagon wrench (width across flats: 8) Remove coupling and collar.

AQ20002-002

2) Remove cover section. Remove the following hexagon socket head bolts: (M14 x 40 x2) (M14 x 65 x2) (M14 x 75 x1) Hexagon wrench (width across flats: 12)

AQ20002-003

3) Grasp both sides of cover and remove it by lifting straight up. Take care to keep the shift piston and control plate from falling off. Place the cover section in a level position immediately after removal. If it is difficult to remove, hammer it out by hitting it lightly with a plastic hammer.

AQ20002-004 AQ15002-002

ASM-17-20-002

Issued 08-2008

Copyright © 8010-5 4) Remove parts from inside the housing: Packing on the mating surface of cover Spring (external) Spring (internal) Guide Take out spring seat.

AQ20002-005

5) Take out rotary group. This is done with the pump on its side.

AQ20002-006

6) Make sure that all pins (dia. 3 x 30 x3) are removed from the housing when removing the rotary group.

AQ20002-007

ASM-17-20-002

Issued 08-2008

Copyright © 8010-6 7) Removing the shaft section. Remove C-shaped snap ring (internal 80). Snap ring pliers (internal snap ring 80).

AQ20002-008

8) Remove the oil seal case. Also, remove the O-ring located in the back of the oil seal case. Two flathead screwdrivers (medium size)

AQ20002-009

9) Withdraw the shaft. If it is difficult to pull out, hit the back end of the shaft lightly with a plastic hammer.

AQ20002-010

ASM-17-20-002

Issued 08-2008

Copyright © 8010-7 10) Take out the swash plate.

AQ20002-011

11) Remove the guides. Remove the guide (delivery side). Remove the guide (suction side).

AQ20002-012

2 Disassembling the cover section 1) Remove the control plate

AQ20002-013

ASM-17-20-002

Issued 08-2008

Copyright © 8010-8 2) Remove the piston. Remove the cylinder. Wrench (width across flats: 27)

AQ20002-014

3) Remove the piston. Remove the Belleville spring and shim.

AQ20002-015

3 Removing the power adjuster (only if required) 1) Loosening the Hexagon nut will change the power setting. Remove hexagon socket head bolts (M10 x 30 x2) and remove cover. Hexagon wrench (width across flats: 8)

AQ20002-016

ASM-17-20-002

Issued 08-2008

Copyright © 8010-9 2) Take out spring seat. Handle carefully. Shim[s] may come out with the spring seat.

AQ20002-017

4 Removing the pilot relief valve (only if required) 1) Disassembling the valve will change the pilot pressure setting. Prior to disassembly, record the screw height and make counter marks. Loosen and remove the locknut and adjusting screw. Remove the spring. Remove the spool. Wrench (width across flats: 24) Wrench (width across flats: 14) NOTE: Using a magnet or M5 bolt will aid removal of the spool.

AQ20002-018

4 Assembling instructions 1 Assembling the cover section 1) Installing the pilot relief valve Install the spool. Install the spring. Fasten the locknut and adjusting screw according to the screw height and counter marks recorded before disassembly. Wrench (width across flats: 14) Wrench (width across flats: 24) Tightening torque: 9.8 Nm.

AQ20002-019

ASM-17-20-002

Issued 08-2008

Copyright © 8010-10 2) Install the spring seat. If the spring seat has a shim, install the shim.

AQ20002-020

3) Install the power adjuster section. Hexagon socket head bolts (M10 x 30 x2) Hexagon wrench (width across flats: 8) Tightening torque: 55 - 69 Nm.

AQ20002-021

2 Installing the cylinder 1) Assemble the piston, Belleville spring and shim into the cylinder and install the assembly on the cover. To keep these parts from falling off when screwing in the cylinder, apply grease to each part.

Cylinder

Piston

NOTE: Apply a small amount of Three Bond No. 1305 to the threaded section of cylinder.

Belleville spring AQ20002-022

ASM-17-20-002

Shim

Issued 08-2008

Copyright © 8010-11 2) Fasten the cylinder. Wrench (width across flats: 27) Tightening torque: 126 - 157 Nm. Install the piston.

AQ20002-023

3) Install the control plate. To keep the control plate from falling off, apply grease to the mating surface with the cover.

AQ20002-024

3 Installing the main pump 1) Install the guide (delivery side). Install the guide (suction side). To keep guides from falling off, apply grease to the mating surfaces with the housing.

AQ20002-025

ASM-17-20-002

Issued 08-2008

Copyright © 8010-12 2) Install the swash plate. To keep the swash plate from falling off, apply grease to the area (spherical) in contact with the guide.

AQ20002-026

3) Install the shaft. Do this with the housing on its side. NOTE: Be careful that the swash plate does not fall off.

AQ20002-027

4) Apply grease to the O-ring and install.

AQ20002-028

ASM-17-20-002

Issued 08-2008

Copyright © 8010-13 5) Install the oil seal case with the oil seal installed. Apply grease to lip section of the oil seal.

AQ20002-029

6) Install C-shaped snap ring (internal 80). Snap ring pliers (internal snap ring 80)

AQ20002-030

7) Assembling the rotary group. Apply grease to pins (dia. 3 x 30 x3) and install them in the spline grooves in the cylinder block.

AQ20002-031

ASM-17-20-002

Issued 08-2008

Copyright © 8010-14 8) Assemble pistons (x10) into retainer, and apply grease to the spherical part of the guide and install it inside retainer. At the same time the pistons are installed into the holes, carefully place the guide on the three pins.

AQ200020-032

9) Install the rotary group. Align the spline with the shaft and install.

AQ20002-033

10) Install the parts in the housing. Place the pump in an upright position, and install the following parts: Spring seat Guide Spring (internal) Spring (external) Packing on the mating surface with the cover.

AQ20002-034

ASM-17-20-002

Issued 08-2008

Copyright © 8010-15 11) Installing the cover section: Install by lowering the cover perpendicularly onto the pump. Verify that packing is straight.

AQ200020-035

12) Fasten the following hexagon socket head bolts: (M14 x 40 x2) (M14 x 65 x2) (M14 x 75 x1) Hexagon wrench (width across flats: 12) Tightening torque: 150 - 180 Nm.

AQ20002-036

13) Install the gear pump: Install the coupling. Attach the collar.

AQ20002-037

ASM-17-20-002

Issued 08-2008

Copyright © 8010-16 14) Installing the gear pump. Hexagon socket head bolts (M10 x 25 x2) Hexagon wrench (width across flats: 8) Tightening torque: 55 - 69 Nm.

AQ200020-038

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

AQ20002-039

2 Disassembling the gear pump (G1) 1) Position as if for pulling out the drive gears and remove the side plate, backup ring, square ring and gears.

AQ20002-040

ASM-17-20-002

Issued 08-2008

Copyright © 8010-17 2) Remove the idle gear.

AQ20002-041

3 Disassembling the gear pump (GSP2) 1) Remove Hexagon bolts (M10 x 95 x4). (AP2D36-904 only) Wrench (nominal: 17)

AQ20002-042

2) Remove the front frame.

AQ20002-043

3) Remove the intermediate frame.

AQ20002-044

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Issued 08-2008

Copyright © 8010-18 4) Remove the square ring.

AQ20002-045

5) Remove the plate, guide and O-ring.

AQ20002-046

6) Remove the plate.

AQ20002-047

7) Remove the drive gear, idle gear and side plate.

AQ20002-048

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Issued 08-2008

Copyright © 8010-19 6 Reassembling gear pump 1 Reassembling the gear pump (GSP2) 1) Install the square ring onto the side plate. NOTE: At this time, pay attention to suction and delivery orientation.

Suction side Delivery side Square ring insertion orientation AQ20002-082 AQ20002-049

2) Install the drive gear and idle gear on the side plate.

AQ20002-050

3) Install the drive gear, idle gear and side plate.

AQ20002-051

4) Install the O-ring on the guide, and then insert them into the plate. Side with larger R Guide

AQ20002-052 AQ20002-053

ASM-17-20-002

Issued 08-2008

Copyright © 8010-20 5) Install the plate, guide and O-ring as an assembly.

AQ20002-054

6) Assemble the 2 plates. NOTE: At this time, pay attention to suction and delivery orientation.

Suction side

Delevery side

AQ20002-056

AQ20002-055

7) Install the drive square ring.

AQ20002-057

8) Assemble the 2 parallel pins into the front frame.

AQ20002-058

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Copyright © 8010-21 9) Install the front frame.

AQ20002-059

2 Assembling the gear pump (G1) 1) Install the drive gear in the housing.

AQ20002-060

2) Install the idle gear.

AQ20002-061

3) Apply grease to the square ring and backup ring to keep them from falling off, and install them into the side plate in that order.

AQ20002-062

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Issued 08-2008

Copyright © 8010-22 4) Install side plate assembled in (3. ) on the housing.

AQ20002-063

5) Assemble the 2 parallel pins into the intermediate frame.

AQ20002-064

6) Install the O-ring on the intermediate frame.

AQ20002-065

7) Install the intermediate frame.

AQ20002-066

ASM-17-20-002

Issued 08-2008

Copyright © 8010-23 8) Using hexagon socket head bolts (M8 x 50, four), fasten the intermediate frame. Hexagon bar wrench (width across flats: 6) Tightening torque: 29 Nm.

AQ20002-067

9) Assemble the 2 parallel pins into the intermediate frame.

AQ20002-068

10) Install the coupling on the end of the shaft on the GSP2 side.

AQ20002-069

11) Connect GSP2 and G1.

AQ20002-070

ASM-17-20-002

Issued 08-2008

Copyright © 8010-24 12) Fasten GSP2 and G1 firmly with hexagon bolts (M10 x 95 x4) Wrench (nominal: 17) Tightening torque: 59 Nm.

AQ20002-071

13) Install the O-ring on the front frame.

AQ20002-072

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2 Structure drawing

AQ20002-073

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Shaft assembly (1) Swash plate assembly (1) Rotary groupt (1) Cover assembly (1) Control spring assembly (1) Control piston assembly (1) Gear pump (1) Housing (1) Air vent valve (1) Bushing (1) Steel ball (1) Plug (1)

ASM-17-20-002

13. 14. 15. 16. 17. 18. 19. 22. 23. 25. 30.

Plug (1) Packing (1) Shim (1) Plug (1) Name plate assembly (1) Plug assembly (1) Plug (1) Plug (1) Orifice (1) Square ring (1) Relief valve assembly (1)

Issued 08-2008

Copyright © 8010-26 1 No. 1 Shaft assembly

#3

AQ20002-074

1. 2. 3. 4.

Shaft (1) Seal case (1) Bearing (1) Retaining ring (C type) (2)

5. Oil seal (1) 6. O-ring (1) 7. Retaining ring (C type) (1)

2 No. 2 Swash plate assembly

AQ20002-075

1. 2. 4. 6.

Swash plate (1) Guide (1) Guide (1) O-ring (1)

ASM-17-20-002

7. 8. 9. 10.

Backup-ring (1) Plug (1) Parallel pin (1) Bushing (1)

Issued 08-2008

Copyright © 8010-27 3 No. 3 Rotary group

AQ20002-076

1. 2. 3. 5.

Piston assembly (10) Cylinder block (1) Retainer (1) Guide (1)

6. 7. 8. 9.

Spring (1) Parallel pin (3) Spring seat (2) Retaining ring (C type) (1)

4 No. 4 Cover assembly

AQ20002-077

1. 2. 3. 4. 5. 6. 7.

Cover (1) Control plate (1) Parallel pin (2) Hexagon socket head bolt M14 x 40 (2) Hexagon socket head bolt M14 x 65 (2) Hexagon socket head bolt M14 x 75 (2) Bearing (1)

ASM-17-20-002

8. 9. 10. 11. 12. 15.

O-ring (1) Square ring (2) Plug assembly (4) Plug (2) Plug (1) Packing (1)

Issued 08-2008

Copyright © 8010-28 5 No. 5 Control spring assembly

AQ20002-078

1. 2. 3. 4. 5. 6. 7.

Spring seat (1) Spring seat (1) Cover (1) Adjust screw (1) Spring (1) Spring (1) O-ring (1)

8. 9. 10. 34. 44. 54.

Hexagon socket head bolt M10 x 30 (2) Hexagon nut M20 (1) Guide (1) Shim (0.3 mm) (2) Shim (0.5 mm) (2) Shim (1.0 mm) (2)

6 No. 6 Control piston assembly

AQ20002-079

1. 2. 3. 4.

Cylinder (1) Piston (1) Piston (1) Coned disc spring (4)

ASM-17-20-002

5. 6. 7. 8.

Distance piece (3.3) (1) Distance piece (3.4) (1) Distance piece (3.5) (1) Distance piece (3.6) (1)

Issued 08-2008

Copyright © 8010-29 7 No. 7 Gear pump

AQ20002-080

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Frame (1) Housing (1) Gear (1) Gear (1) Thrust plate (1) Metal (4) Backup-ring (1) Parallel pin (4) Square ring (1) Coupling (1) Retaining ring (C type) (1)

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Hexagon socket head bolt M8 x 55 (4) O-ring (1) Frame (1) Hexagon head bolt M10 x 25 (4) O-ring (1) O-ring (1) O-ring (1) O-ring (2) O-ring (1) Bushing (1) Hexagon socket head bolt M10 x 25 (2)

8 No. 30 Relief valve assembly

AQ20002-081

1. Spool (1) 2. Adjusting screw (1) 3. O-ring (1)

ASM-17-20-002

4. Spring (1) 5. Hexagon nut (1) 6. Shim (1)

Issued 08-2008


NOTES .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... 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ASM-17-20-002

Issued 08-2008

8011 Section 8011 DISASSEMBLY AND ASSEMBLY OF THE MAIN HYDRAULIC CONTROL VALVE

CX80 TIER 3

CNH

Lep SM80-8011-0EN


8011-2

TABLE OF CONTENTS CONTROL VALVE................................................................................................................................................... 3 MAINTENANCE INSTRUCTIONS ................................................................................................................................ 3 Disassembling ................................................................................................................................................... 3 Disassembling Procedures ............................................................................................................................... 3 CLEANING ............................................................................................................................................................. 7 INSPECTION........................................................................................................................................................... 7 ASSEMBLING......................................................................................................................................................... 7 Subassemblies .................................................................................................................................................. 7 Assembling the Control Valve Main Body ......................................................................................................... 9 RELIEF VALVES ................................................................................................................................................... 13 Instructions for Disassembling and Assembling the Main body Relief Valves ................................................ 13 Instructions for Disassembling and Assembling the Add-on Relief Valves ..................................................... 14 Instructions for Disassembling and Assembling the Overload Relief Valves .................................................. 15 Instructions for Disassembling and Assembling the Negative Control Relief Valves ...................................... 15 Adjusting the Relief Valves ............................................................................................................................. 16 INSTALLATION ..................................................................................................................................................... 16 OPERATION ......................................................................................................................................................... 16 LIST OF CONTROL VALVE SPECIFICATIONS ............................................................................................................ 17 TROUBLESHOOTING............................................................................................................................................. 17 Control valves in general................................................................................................................................. 17 Relief valves .................................................................................................................................................... 18 Hydraulic system in general ............................................................................................................................ 18 REFERENCE DRAWING ........................................................................................................................................ 19 Parts list .......................................................................................................................................................... 19 Overall View 1/3 .............................................................................................................................................. 20 Overall View 2/3 .............................................................................................................................................. 22 Overall Drawing 3/3......................................................................................................................................... 25 Reference number (2): Spool section assembly ............................................................................................. 28 Reference number (3): Inlet section assembly................................................................................................ 29 Reference number (40): Anti-drift valve assembly .......................................................................................... 30 Reference number (29): Shut-off valve assembly ........................................................................................... 31

Lep SM80-8011-0EN

Issued 08-2008

8011-3

CONTROL VALVE 1 Maintenance instructions 1 Disassembling [1] Disassembling Precautions 1) Stop the engine after the pressure in the actuator has been completely released.

!

WARNING: Do not replace valve assemblies or disassemble valves when unreleased pressure remains. Pressurized hydraulic oil may spray out, or parts may fly out under pressure. When disassembling, place the bucket firmly on the ground, and then completely release the pressure from the circuits. 2) Release the air pressure from the tank. 3) Thoroughly clean around the area to be disassembled to prevent any foreign substances from getting into the valves during disassembly. 4) Put tags on the disassembled parts so that their location can be easily identified for reassembly. 5) Replace all disassembled seals with new ones (O-rings and backup rings). 6) Do not replace spools, because they are selectively fit with their valve housings and sleeves.

2 Disassembling Procedures * Numbers for parts contained in an assembly are expressed as (assembly no. - part no.). 1 Disassembling the main spools (2 through 10) (80-2) 1) Loosen socket head bolts (65) (80-12) (WAF: 6), and disassemble long caps (11 and 15) (80-3). Remove Orings (12) (80-4) from the grooves in the valve housing. 2) Loosen socket head bolt (66) (WAF: 5), and disassemble caps (46 and 47). Remove O-ring (42) from the cap. 3) Pull each spool out of the valve housing as a subassembly.

!

WARNING: Pull the spools straight up so they will not be dented or scratched. If the spools are dented or scratched, they may damage the holes in the body as they come out and may not fit back in at reassembly. Even if they go in, they may not operate correctly. Place tags on each spool so that their location can be easily identified for reassembly. If a wrong spool is installed, the actuator will not function properly, and this is extremely dangerous. 4) Loosen socket head bolts (65) (80-12) (WAF: 6) and disassemble short caps (13 and 14) (80-5). Remove Orings (12) (80-4) from the grooves of the valve housing. 5) Loosen spool ends (2-4, 3-4, 4-4, 5-4, 7-4, 9-4, 10-4 and 80-2-4; WAF: 6) of spools (2 to 5, 7, 9, 10 and 8-2), and remove spring seats (2-2, 3-2, 4-2, 5-2, 7-2, 9-2, 10-2 and 80-2-2) and springs (2-3, 3-3, 4-3, 5-3, 7-3, 9-3, 10-3 and 80-2-3). 6) Loosen spool end (6-4) (WAF: 6) of spool (6), then remove spring seat (6-2) and spring (6-3). Loosen plug (6-5; groove width 3) and remove poppet (6-6), spring (6-7), O-ring (6-8) and backup ring (6-9). 7) Loosen spool end (8-4) (WAF: 6) of spool (8), then remove spring seat (8-2) and spring (8-3). Loosen plug (8-5; groove width 3), then remove poppet (8-6), spring (8-7), O-ring (8-8) and backup ring (8-9).

ASM-19-07-001

Issued 08-2008

8011-4

!

WARNING: Secure the spool between blocks in a vise in order to avoid damaging the spool during disassembly. At this time, secure the spool as close to the spool end as possible to avoid bending the spool. Adhesive is applied to the threaded part of the spool end. Use an industrial dryer to heat the threaded part of the outside of the spool until the spool end can be easily tightened (heating temperature should be 200 to 250°C). Replace with a new one if overheated. Overheating may cause thermal deformation of the spring, resulting in poor performance and durability. Note that the spring will be extremely hot after it is heated. Handle with care to avoid burns from direct contact with bare hands.

Blocks for spool disassembly/reassembly AS07001-001

2 Disassembling the subassembly spools (41 and 48) 1) Loosen spool ends (43) (WAF: 5) of spools (41 and 48), then remove spring seats (43) and spring (44). 2) Adhesive is applied to the threaded parts of the spool and to the joint section of the spool end. Disassemble following the note above. 3 Disassembling the sub-spool section (52) 1) Loosen plug (49) (WAF: 32) and remove O-ring (50). 2) Remove spring (51) and pull out spool (52-1). 3) Draw it out by hooking a wire inside the hole on the near side of the sleeve (52-2). Piston (52-3) is pulled out at the same time. 4) Remove backup ring (53) and O-ring (54). 4 Disassembling the boom and arm anti-drift valves 1) Loosen socket head bolt (67) (WAF: 6), remove body assembly (30), and then remove O-ring (31) from the groove on the housing.

!

WARNING: If the control valve is attached to the machine during disassembly, unreleased pressure can cause parts to fly out. Loosen socket head bolt (67) slowly, and verify that there is no more resistance from unreleased pressure. 2) Remove spacer assembly (29) using a M6 x 1.0 screw, and then remove O-rings (29-2 and 29-4) and backup ring (29-3). 3) Remove spring (28) and poppet (27). 4) Secure body assembly (30) in a vise, taking care not to damage the mating face on the mounting side of Oring (31). 5) Loosen plug assembly (30-14) (WAF: 38) and remove O-ring. 6) Pull out piston (30-4), spool (30-5) and spring (30-7). 7) Loosen plug (30-3) (WAF 38) and remove O-ring (30-13).

ASM-19-07-001

Issued 08-2008

8011-5

!

WARNING: If the control valve is attached to the machine during disassembly, unreleased pressure can cause parts to fly out. Loosen plug (30-3) slowly, and verify that there is no more resistance from unreleased pressure. 8) Pull out sleeve (30-6) and poppet (30-2). Remove O-rings (30-9 and 30-10) and backup rings (30-11 and 30-12) from around the sleeve. 9) Pull out spring seat (30-15) and spring (30-8) from the back of the hole.

5 Disassembling Travel Right, Swing, Bucket, Booms 1 and 2, Arm1 and Blade load check sections 1) Loosen plug (19) (80-9) (WAF: 27) on the load check and remove O-ring (18) (80-8) from the plug. 2) Remove spring (17) (80-7) and poppet (16) (80-6). 6 Disassembling the check on the Travel Straight restrictor section (Travel Left section) 1) Loosen plug (19) (WAF: 27) on the Travel Straight restrictor section and remove O-ring (18) from the plug. 2) Pull out poppet (26) and spring (17). 7 Disassembling the Arm 2 load check section 1) Loosen socket head bolt (68) (WAF: 8) and remove flange (39) from the main body. Remove O-ring (38) from the groove of the valve housing. 2) Remove sleeve (33), springs (35 and 37) and poppets (34 and 36).

!

WARNING: Use caution to keep the springs from falling into the passage. If a spring falls into the passage, it may get caught on the main spool sliding section, and the spool will stick, which may cause the actuator to overrun unstoppably.

8 Disassembling the backup external confluence check section 1) Loosen plug (23) (WAF: 32) and remove O-ring (18) from the plug. 2) Take out spring (25) and poppet (24). 3) Loosen plug assembly (81) (WAF: 27) and remove the O-ring. 9 Disassembling the common check section 1) Loosen plug (19) (WAF: 27) on the check, then remove O-ring (18) from the plug. 2) Take out spring (17) and poppet (16). 10 Disassembling the Arm 1 semi-parallel check section 1) Loosen plug assembly (32) (WAF: 8) and remove the O-ring. 2) Take out spring (58) and poppet (57). 11 Disassembling the relief valves 1) Remove overload relief valve (63) (WAF: 32) from the main body valve and the add-on spool section. 2) Remove main relief valve (62) (WAF: 32) from the main body valve and main relief valve (79) (WAF: 24) from the add-on inlet section. 3) Remove negative control relief valve (55) (WAF: 32) from the main body valve. * For disassembly and reassembly of relief valves, refer to appropriate chapter in Section.

ASM-19-07-001

Issued 08-2008

8011-6 12 Disassembling the shut-off valves 4) Loosen plug assembly (64) (WAF: 32), then remove O-rings and backup rings. 13 Disassembling the other plugs 1) Loosen plug assembly (20) (WAF: 19) on the Port PP section and remove the O-ring. 2) Loosen plug (89) (WAF:19) on the backup cap section and remove the O-ring (88). 3) Disassemble G1/8 size plugs (21) (WAF: 5; 3 locations in all), then remove the O-rings. 4) Disassemble G3/8 size plugs (32) (61-2) (WAF: 8; 4 locations in all), then remove the O-rings. 5) Disassemble G1/2 size plugs (69) (78-2) (WAF: 10; 2 locations in all), then remove the O-rings. 6) Disassemble G3/4 size plugs (90) (WAF: 36; 2 locations in all), then remove the O-rings. 7) Disassemble 7/8-14 UN size plug (22) (WAF: 27) and remove O-ring (18). 14 Disassembling the add-on section 1) Loosen and remove hexagonal nuts (72) (WAF: 19) and (74) (WAF: 22). 2) Pull out outlet housing (61-1). 3) Pull out the valve housing for the spool section (80-1) and remove O-rings (80-10 and 80-11) for the mating surface. 4) Pull out inlet housing (78-1) and remove the O-rings (78-3 and 78-4) from the mating surfaces. 5) Remove O-rings (59 and 60) from the mating surfaces on the main body. 6) Loosen tie rods (71 and 73) and remove from main body valve housing (1). (Use a pipe wrench or the like).

!

WARNING: When pulling out the add-on section, be careful not to dent or scratch the mating surfaces. If they are dented or scratched, malfunctioning may occur due to oil leakage from the mating surfaces. Also, use caution to prevent foreign substances from getting into the oil passages. Foreign substances may lodge in the spool sliding section causing the spool to stick, and faulty seating of the load check may cause the actuator to overrun unstoppably.

ASM-19-07-001

Issued 08-2008

8011-7

2 Cleaning Thoroughly clean all disassembled parts with clean mineral oil. Dry with compressed air and place each part on a clean paper or vinyl surface for inspection.

3 Inspection Inspect all surfaces of each part for burrs, scratches or other damage. 1) Check for scratches and nicks, dents, dirt, and rust on the load check seat surfaces in the valve housing, and remove small scratches an oilstone. 2) Check for scratches, dents and other damage on the outside of the spool, and remove small scratches with an oilstone. 3) All sliding parts should move smoothly, and there should be no foreign substances in any grooves or passages. 4) Broken, severely deformed, or worn springs must be replaced. 5) If the relief valve is not working properly, inspect according to 5. Adjusting the Relief Valves. 6) All O-rings and backup rings on the disassembled parts must be replaced with new ones. 7) After removing caps and plugs, check to see that there is no paint around the holes in the body or on the plug seats. (If paint chips get into the valve, binding or blockage may occur, leading to malfunctioning or oil leakage).

4 Assembling

!

WARNING: Prior to assembly, verify the number of parts, locations for installation and tools required.

1 Subassemblies * Before installing parts onto the valve housing body, assemble the required parts into subassemblies. 1 Main spools (2 to 10) (80-2) Apply adhesive to the threaded parts of spools (2 to 5, 7, 9, 10 and 80-2). 1) Install spring seats (2-2, 3-2, 4-2, 5-2, 7-2, 9-2, 10-2 and 80-2-2), springs (2-3, 3-3, 4-3, 5-3, 7-3, 9-3, 10-3 and 80-2-3) and spool ends (2-4, 3-4, 4-4, 5-4, 7-4, 9-4, 10-4 and 80-2-4). Secure the spool between blocks in a vise and tighten the spool end. Tightening torque: 9.8 to 11.8 Nm

!

WARNING: Do not apply too much adhesive. Excess adhesive will overflow when the spool is tightened. Grasp the spool as close as possible to the end so that the spool is not bent by the tightening torque. If the spool end is overtorqued, swelling of the spool may cause it to stick, and this may cause the actuator to everrun unstoppably. * Observe this precaution when adhesive is used in the instructions below.

!

WARNING: Springs (5-3 and 10-3) on Boom 2 spool (5) and Travel Straight spool (10) are different from the springs for other parts. Installing incorrect parts may lead to malfunctioning of the actuator.

ASM-19-07-001

Issued 08-2008

8011-8 2) Install poppet (6-6) and spring (6-7) into the hole in spool (6). Next, apply adhesive to the threaded part of the spool. Secure the spool between blocks in a vise. Apply adhesive to the threaded part of plug (6-5). Install O-ring (6-8) and backup ring (6-9) onto plug (6-5), then fasten the plug. Tightening torque: 9.8 to 11.8 Nm Install the spring seat (6-2), springs (6-3) and spool end (6-4), then fasten the spool end. Tightening torque: 9.8 to 11.8 Nm Install poppet (8-6) and spring (8-7) into the hole in spool (8). Next, apply adhesive to the threaded part of the spool to which plug (8-5) is to be installed. Install O-ring (8-8) and backup ring (8-9) onto plug (8-5), then fasten the plug. Tightening torque: 9.8 to 11.8 Nm Apply adhesive to the threaded part of spool to which spool end (8-4) is to be installed. Install spring seat (8-2), spring (8-3) and spool end (8-4). Secure the spool between blocks with a vise and tighten the spool end. Tightening torque: 9.8 to 11.8 Nm.

!

WARNING: Be careful to assemble O-rings and backup rings in the correct locations. If installed backwards, Orings may break and this may lead to malfunctioning.

2 Sub-spool section (41 and 48) 1) Apply adhesive to the threaded parts of spools (41 and 48). 2) Install spring seat (43), spring (44) and spool end (45). Secure the spool between blocks in a vise and tighten spool end (45). Tightening torque: 19 to 22 Nm. 3 Sub-spool section (52) 1) Install backup ring (53) and O-ring (54) on sleeve (52-2). 2) Install a seal onto sleeve (52-2), then install piston (52-3) into the sleeve. 3) Insert spool (52-1) into sleeve (52-2). 4 Boom and arm anti-drift valves 1) Install O-rings (30-9 and 30-10) and backup rings (30-11 and 30-12) in the groove around sleeve (30-6).

!

WARNING: Be careful to assemble O-rings and backup rings in the correct locations. If installed backwards, Orings may break and increase the natural drop of the actuator. 2) Insert poppet (30-2) and spool (30-5) into the sleeve holes, taking care to orient them correctly. 3) Attach spring seat (30-15) onto the smaller poppet end, place spring (30-8) on spring seat, and then insert together with sleeve into the hole in body (30-1). 4) Secure body (30-1) in a vise so that the mating faces of the body and the fitting side of the O-ring (31) are not damaged.

!

WARNING: Apply grease to seats so that the springs and the spring seats are seated firmly on the poppet. If the spring is not seated on the spring seat, the spring may be broken by the spring seat, and the broken pieces may travel through the flow passage and cause malfunctioning of moving parts. 5) Install spring (30-7) and piston (30-4) onto plug (30-3). 6) Install an O-ring on plug assembly (30-14), then tighten the assembly onto plug (30-3). Tightening torque: 147 to 157 Nm 7) Install O-ring (30-13) on plug (30-3), then tighten the plug onto body (30-1). Tightening torque: 147 to 167 Nm.

ASM-19-07-001

Issued 08-2008

8011-9 5 Shut-off Valve 1) Install spring (30-7) and piston (30-4) onto plug (30-3).

!

WARNING: Be careful to assemble O-rings and backup rings in the correct locations. If installed backwards, Orings may break and lead to malfunctioning.

2 Assembling the Control Valve Main Body 1 Assembling the add-on section 1) Install tie rods (71 and 73) onto the main body valve housing (1).

!

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

!

WARNING: Oil leaking from mating surfaces can cause malfunctioning. Be careful not to dent or scratch the mating surfaces when installing add-on sections. At the same time, be careful to keep foreign substances from lodging between mating surfaces and to keep O-rings from falling off or protruding.

!

WARNING: When installing add-on sections, always install the tie rod first and use it as a guide in positioning the installation. If positioned without using the tie rod, the incorrectly aligned O-ring on the mating surface may cause oil leakage, which may cause malfunctioning. 6) Fasten hexagonal nut (74) onto tie rod (73). Tightening torque: 152 ± 7 Nm Fasten hexagonal nut (72) onto tie rod (71). Tightening torque: 93 ± 4 Nm

!

WARNING: Always fasten hexagonal nuts to within the specified torque range. Undertorquing may cause oil leakage from the mating surfaces due to lack of fastening force. Overtorquing may cause the spool to stick due to distortion of the valve housing for the spool section, causing the actuator to overrun unstoppably. Tighten the two nuts alternately so that they will be tightened equally.

!

WARNING: This control valve is designed so that add-on sections supplied as kits can be added on afterwards. When adding add-on sections, always follow the same precautions as for disassembly and reassembly.

ASM-19-07-001

Issued 08-2008

8011-10 2 Assembling Travel Right, Swing, Bucket, Booms 1 and 2, Arm 1 and Blade load check sections 1) Insert poppets (16) (80-6) and springs (17) (80-7) into the valve housing. 2) Install O-rings (18) (80-8) on plugs (19) (80-9), then screw in and tighten the plugs. Tightening torque: 103 to 113 Nm 3 Assembling the Arm 2 load check section 1) Assemble spring (35) and poppet (34) around the perimeter inside sleeve (33), then insert the sleeve into the valve housing with poppet (36) and spring (37) inside. 2) Install O-ring (38) onto the groove of the valve housing. Install flange (39) and fasten with socket head bolts (68). Tightening torque: 39 to 44 Nm

!

WARNING: When installing flange (39), ensure that spring (37) is firmly seated in the flange seat. If the spring is not seated when assembled, it may break. When tightening socket head bolts (68), tighten the 2 bolts alternately so that they will be tightened equally. Observe this precaution when fastening flanges in the instructions below.

4 Assembling the check on the Travel restrictor section (Travel Left section) 1) Insert poppet (26) and spring (17) into the valve housing. 2) Install O-ring (18) on plug (19), then fasten the plug. Tightening torque: 103 to 113 Nm.

!

WARNING: When installing the flange (19), ensure that the spring (17) is firmly seated in the plug seat. If the spring is not seated firmly when assembled, it may break. Observe this precaution when fastening plugs in the instructions below.

5 Assembling the backup external confluence check section 1) Insert poppet (24) and spring (25) into the valve housing. 2) Install O-ring (18) on plug (23) and fasten the plug. Tightening torque: 103 to 113 Nm 3) Install O-ring on plug assembly (81) and fasten the assembly. Tightening torque: 89 to 97 Nm. 6 Assembling the common check section 1) Insert poppet (16) and spring (17) into the valve housing. 2) Install O-ring (18) on plug (19) and fasten the plug. Tightening torque: 103 to 113 Nm 7 Assembling the Arm 1 semi-parallel check section 1) Insert poppet (57) and spring (58). 2) Install O-ring on plug (32) and fasten the plug. Tightening torque: 73 to 79 Nm

ASM-19-07-001

Issued 08-2008

8011-11 8 Assembling the boom and the anti-drift valve 1) Install O-ring (31) on the mating surface. 2) Insert poppet (27) into the valve housing. 3) Install O-rings (29-2 and 29-4) and backup ring (29-3) on spacer (29-1). Press the spacer into the valve housing together with spring (28).

!

WARNING: Be careful to assemble so that the spring is seated correctly on the spacer seat. If the spring is not seated on the spacer, it may be broken by the poppet, and broken pieces may travel through the flow passage and cause malfunctioning of moving parts. 4) Pass socket head bolt (67) through body assembly (30) and fasten. Tightening torque: 20 to 25 Nm

9 Assembling the relief valves 1) Screw in overload relief valves (63) and tighten: total 8 locations. Tightening torque: 78 to 88 Nm 2) Screw in main body main relief valve (62) and tighten. Tightening torque: 78 to 88 Nm 3) Screw in add-on main relief valve (79) and tighten. Tightening torque: 49 to 59 Nm 4) Screw in negative control relief valve (55) and tighten. Tightening torque: 103 to 113 Nm. 10 Assembling the subassembly spools (41 and 48) 1) Assemble spool assemblies (41 and 48) in the same locations as before disassembly. 2) Install O-rings (42) on caps (46 and 47) and install the caps. Pass socket head bolt (66) through the caps and fasten. Tightening torque: 8.8 to 10.5 Nm.

!

WARNING: Hold the spool perpendicular to the hole and insert slowly. After insertion, slide the spool back and forth by hand to make sure it does not move unevenly or roughly. If the spool is inserted so that it moves unevenly or roughly, it may malfunction. Observe this precaution when inserting spools in the instructions below.

11 Assembling the sub-spool (52) 1) Assemble spool assembly (52) in the same location as before disassembly. 2) Install spring (51). 3) Install O-ring (50) on plug (49) and fasten the plug. Tightening torque: 103 to 113 Nm

ASM-19-07-001

Issued 08-2008

8011-12 12 Assembling the main spools (2 through 10) (80-2) 1) Install O-ring (12) (80-4) on the valve housing (1) (80-1). 2) Install short cap (14) on Travel Straight spool (10). Install short caps (13) (80-5) on all the other spools. Pass socket head bolts (65) (80-12) through the caps and fasten. Tightening torque: 20 to 25 Nm 3) Install spools (2 through 10) (80-2), assembled as a subassemblies, into spool holes in the same locations as before disassembly. 4) Install long cap (15) on Travel Straight spool (10). Install long caps (11) (80-3) on all the other spools. Pass socket head bolt (65) through the long caps and fasten. Tightening torque: 20 to 25 Nm.

!

WARNING: Be careful that the mating surface O-rings do not fall off when installing the caps.

13 Assembling the other plugs 1) Install an O-ring on plug assembly (90) and fasten the assembly. Tightening torque: 205 to 227 Nm 2) Install O-rings on plug assemblies (32) (61-2) and fasten the assemblies. Tightening torque: 73 to 79 Nm 3) Install an O-ring on plug assembly (21) and fasten the assembly. Tightening torque: 13.5 to 16.5 Nm 4) Install an O-ring on plug assembly (22) and fasten the assembly. Tightening torque: 103 to 113 Nm 5) Install O-rings on plug assemblies (69) (78-2) and fasten the assemblies. Tightening torque: 116 to 128 Nm 6) Install an O-ring on plug assembly (20) and fasten the assembly. Tightening torque: 49 to 59 Nm 7) Install an O-ring on plug assembly (89) and fasten the assembly. Tightening torque: 19 to 22 Nm

!

WARNING: After completing the assembly, check for parts that may have been forgotten or not tightened. Forgetting to tighten parts will cause oil leakage from loose parts. All tightening torque values are for under wet conditions (with hydraulic oil applied).

ASM-19-07-001

Issued 08-2008

8011-13

5 Relief valves 1 Instructions for Disassembling and Assembling the Main body Relief Valves

AQ23002-001

[1] Disassembling This component must be replaced as an assembly. When disassembling, loosen plug (1) (WAF: 32) with a wrench or the like and remove O-ring (2). If oil is leaking from the adjuster kit section (3), loosen the kit and replace the O-rings (4).

!

WARNING: When disassembling the adjuster kit, be careful that parts do not fly out due to the spring, and be careful not to lose the poppet.

[2] Assembling Make sure there is no dirt or paint chips around the threaded section of plug (1) and install a new O-ring (2). Thoroughly clean the area where the relief valve is to be installed on the valve housing as well. Install the relief valve and fasten plug (1). Tightening torque: 59 to 69 Nm If the adjuster kit has been disassembled, thoroughly clean around the threaded part, then adjust the pressure according to 5. Adjusting the Relief Valves.

!

WARNING: All the above tightening torque values are for under wet conditions (with hydraulic oil applied).

ASM-19-07-001

Issued 08-2008

8011-14 2 Instructions for Disassembling and Assembling the Add-on Relief Valves [1] Disassembling This component must be replaced as an assembly. When replacing, loosen plug (1) (WAF: 32) with a wrench or the like and remove O-ring (2). If there is leakage from the adjuster kit section (3), loosen the adjuster kit and replace the O-rings (4).

!


[2] Assembling Make sure there is no dirt or paint chips around the threaded section of plug (1) and install a new O-ring (2). Thoroughly clean the area where the relief valve is to be installed on the valve housing as well. Install the relief valve and fasten plug (1). Tightening torque: 59 to 69 Nm If the adjuster kit has been disassembled, thoroughly clean around the threaded part, then adjust the pressure according to 5. Adjusting the Relief Valves.

!


ASM-19-07-001

Issued 08-2008

8011-15 3 Instructions for Disassembling and Assembling the Overload Relief Valves

AQ23002-002

[1] Disassembling This component must be replaced as an assembly. When replacing it, loosen cap (1) (WAF: 32) with a wrench, etc. and remove O-ring (2). If there is a leak from the adjuster kit section (3), loosen the adjuster kit and replace the O-rings (4).

!


[2] Assembling Make sure there is no dirt or paint chips around the threaded section of cap (1) and install a new O-ring (2). Thoroughly clean the area where the relief valve is to be installed on the valve housing as well. Install the relief valve and fasten cap (1). Tightening torque: 78 to 88 Nm If the adjuster kit has been disassembled, thoroughly clean around the threaded part, and adjust the pressure according to 5. Adjusting the Relief Valves.

!


4 Instructions for Disassembling and Assembling the Negative Control Relief Valves 1 Disassembling This component cannot be disassembled because Section D is press fit. It must be replaced as an assembly. 2 Assembling Make sure there is no dirt or paint chips around the threaded section of plug (1) and install a new O-ring (3). Install a new O-ring (4) on sleeve (2). Thoroughly clean the area where the relief valve is to be installed on the valve housing as well. Install and fasten the relief assembly plug (1). Tightening torque: 103 to 113 Nm

!


ASM-19-07-001

Issued 08-2008

8011-16 5 Adjusting the Relief Valves 1 Main relief valves (procedure is the same for the main body and add-on relief valves) 1) Attach an accurate pressure gauge at the entry circuit. 2) Run the pump at its rated rpm. 3) Switch spools on the control valve. Read the pressure gauge with the cylinder at stroke end.

!

WARNING: Switch spools on the actuator, in which the set pressure of the overload relief valve is higher than that of the relief valve. 4) Turn the adjuster clockwise until the required pressure is obtained. One turn of the adjuster increases the pressure by 17.8 MPa. 5) When the pressure reaches the specified value, press down on the adjuster to stop the rotation, then fasten the lock nut. Tightening torque: 27 to 31 Nm

2 Overload Relief Valve

!

WARNING: If the set pressure of the overload relief valve is higher than that of the main relief valve, do not adjust the overload relief valve. Replace it with a pre-set relief valve as an assembly. 1) Switch spools on the control valve. Read the pressure gauge with the cylinder at stroke end. 2) Turn the adjuster clockwise until the required pressure is obtained. One turn of the adjuster increases the pressure by 21.2 MPa. 3) When the pressure reaches the specified value, press down on the adjuster to stop the rotation, then fasten the lock nut. Tightening torque: 27 to 31 Nm 4) Increase the pressure again to verify that the specified pressure has been obtained.

6 Installation 1) Piping should be done with caution to avoid excessive outside pressure on the valves. 2) Fasten all mounting bolts equally. 3) Use caution when welding closely to the valves. Seals may be damaged by excessive heat and sputter. 4) To keep foreign substances from getting into ports, do not remove coverings until starting piping work.

7 Operation 1) Verify that hydraulic circuits and hydraulic oil are clean before starting operation. 2) Use hydraulic oil with an aniline point between 82 and 113 °C. 3) Do not exceed the specified set pressure of the relief valve. 4) There must be a difference of 2.0 MPa or more between the set pressures of the main valve and the overload valve. 5) Bleed air and warm up the machine completely before actual operation. In particular, if the hydraulic oil temperature and the valve temperature are low, follow the precautions below at start-up in order to prevent the spool from sticking due to heat shock: • Do not attempt sudden continuous operation of the main relief valve or the overload valve. Let the hydraulic oil in all the actuators circulate so the temperature rises uniformly in all the sections. • Sudden fine adjustments or combined operations at low temperatures generate heat locally due to throttling of all sections and must be avoided.

ASM-19-07-001

Issued 08-2008

8011-17

8 List of control valve specifications Rated flow (main body): 160 L/min (Note: 30 L/min in neutral) Maximum pressure (main body): 35 MPa Rated flow (add-on Pr): 70 L/min Maximum pressure (add-on Pr): 28 MPa Allowable back pressure Peak pressure: < or = 1.5 MPa Pressure for normal operation: > or = 0.5 MPa Allowable oil operating temperature range For normal operations: -25 to 80°C Instantaneous maximum: 100°C (Nitrile rubber is used for seals)

9 Troubleshooting 1 Control valves in general Problem

Spool does not cycle.

Cause

Remedy

1. Abnormal increase in oil temperature.

Remove cause of resistance in oil flow from pipe.

2. Dirty hydraulic oil.

Replace hydraulic oil and clean circuit.

3. Over-tightened port joints in piping.

Check torque.

4. Valve housing deformed at time of installation.

Loosen mounting bolts and check.

5. Pressure is too high.

Attach pressure gauges to pump port and cylinder port to check pressure.

6. Spool is bent.

Replace as a valve assembly.

7. Damaged return spring.

Replace damaged parts.

8. Spring or cap is crooked.

Loosen cap; center and retighten.

9. Uneven temperature distribution in valve.

Warm up entire circuit.

10. Valve is blocked by dirt.

Flush to remove dirt.

11. Insufficient pilot pressure.

Check pilot valve and pilot relief pressure.

1. Oil leakage from cylinder.

Check cylinder seals.

2. Oil bypassing from spool.

Check spool for damage.

3. Oil leakage from overload relief valve.

Clean valve housing seat and relief valve seat.

4. Oil leakage from anti-drift valve.

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

1. Dirt in load check valve.

Disassemble and clean check valve.

2. Damaged poppet or seat in check valve.

Replace poppet, or lap poppet and seat.

Cannot hold load.

Load drops when spool is switched from neutral to upward position.

ASM-19-07-001

Issued 08-2008

8011-18 2 Relief valves Problem

Cause

Pressure does not rise at all.

1. Main poppet, sleeve or pilot poppet is stuck open, or there is dirt in the seat section.

Unstable relief pressure. Incorrect relief pressure.

1. Pilot poppet seat is damaged.

Replace relief valves.

2. Piston or main poppet is stuck. 1. Seat is worn by dirt. 2. Loose lock nut or adjuster. 1. Damaged seat in relief valve.

Oil leakage.

Remedy

2. Parts are stuck because of dirt. 3. Worn O-ring.

Reset pressure, then fasten lock nut to specified torque. Replace relief valves. Replace adjusters or O-rings in mounting section.

3 Hydraulic system in general Problem

Hydraulic system does not function properly or does not operate at all.

ASM-19-07-001

Cause

Remedy

1. Faulty pump.

Check pressure or replace pumps.

2. Faulty relief valve.

Replace relief valves

3. Faulty cylinder.

Repair or replace.

4. Pump load pressure is too high.

Check pressure in circuit.

5. Cracks on valves.

Replace as a valve assembly.

6. Incomplete spool stroke.

Check spool movement.

7. Oil level in tank is too low.

Refill with hydraulic oil.

8. Blocked filter in circuit.

Clean or replace filter.

9. Restricted piping in circuit.

Check piping.

Issued 08-2008

8011-19

10Reference Drawing 1 Parts list Sym

Part name

Q’ty

Sym

Part name

Q’ty

Sym

Part name

Q’ty

1

Valve housing

1

29

Spring

1

57

Plug

1

2

Spool section assembly

1

30

Spool

1

58

Shut-off valve assembly

2

3

Inlet section assembly

1

31

Plug

1

59

Plug

1

4

Spool

1

32

Spring

1

60

Relief valve kit

6

5

Spool

1

33

Outlet housing

1

61

Relief valve kit

1

6

Spool

1

34

Spacer

2

62

Plug assembly

1

7

Spool

1

35

O-ring

2

63

Plug assembly

2

8

Spool

1

36

Backup ring

2

64

Plug assembly

1

9

Spool

1

37

Sleeve

1

65

Plug

3

10

Spool

1

38

Plate

1

66

O-ring

3

11

Spool

1

39

Socket head bolt

44

67

Plug

1

12

Spool

1

40

Anti-drift valve assembly

1

68

Spacer

2

13

Spool

1

41

Poppet

1

69

Poppet

2

14

Cap

10

42

Spring

1

70

Spring

2

15

Cap

10

43

Socket head bolt

4

71

Tie rod

4

16

Spring

8

44

Sleeve

1

72

Nut

4

17

Spool end

10

45

Poppet

3

73

O-ring

1

18

Spring seat

20

46

Spring

3

74

O-ring

2

19

O-ring

20

47

Poppet

2

75

O-ring

1

20

Spring

2

48

Plug

3

76

O-ring

1

21

Plug assembly

1

49

Spring

2

77

Name plate

1

22

Sleeve

1

50

O-ring

4

78

Drive screw

4

23

O-ring

1

51

Sleeve

1

79

O-ring

2

24

Backup ring

2

52

Poppet

5

80

Spool section assembly

1

25

Plug assembly

14

53

Spring

5

81

Relief valve kit

1

26

Poppet

1

54

Plug

4

82

Relief valve kit

2

27

Spring

1

55

O-ring

7

28

Plug assembly

7

56

Poppet

1

ASM-19-07-001

Issued 08-2008

8011-20 2 Overall View 1/3

Arm 1 Boom 2 Swing Backup Travel (right)

KAJ5076S1D01

ASM-19-07-001

Issued 08-2008

8011-21

Blade

W-W

Boom swing

Arm 2 Boom 1

Bucket Travel (left) Travel (Straight)

KAJ5076S1D01

ASM-19-07-001

Issued 08-2008

8011-22 3 Overall View 2/3

Arm 1

Boom 2

Swing

Option

Travel (right)

5 spool side A-A KAJ5076S2D01

ASM-19-07-001

Issued 08-2008

8011-23

Blade

Boom swing

Arm 2

Boom 1

Bucket

Travel (left)

Travel (straight)

KAJ5076S2D01

B-B (4-Speed side)

ASM-19-07-001

Issued 08-2008

8011-24

D-D

Arm 1

Arm 2

KAJ5076S2D01

E-E

ASM-19-07-001

Issued 08-2008

8011-25 4 Overall Drawing 3/3

Boom 2

Boom 1

F-F

Travel (right)

Travel (straight)

KAJ5076S3D01

I-I

ASM-19-07-001

Issued 08-2008

8011-26

Swing

Bucket

G-G

KAJ5076S3D01

J-J

ASM-19-07-001

Issued 08-2008

8011-27

Option

Travel (left)

KAJ5076S3D01

H-H

ASM-19-07-001

Issued 08-2008

8011-28 5 Reference number (2): Spool section assembly

W

W

KAJ5076S6B00

W-W 1. 2. 3. 4. 5. 6. 7. 8. 9.

Valve housing (1) Spool (1) Cap (1) Cap (1) Spool end (1) Spring (1) Spring seat (2) Poppet (1) Plug (1)

ASM-19-07-001

10. 11. 12. 13. 14. 15. 16. 17.

Spring (1) O-ring (2) O-ring (2) O-ring (1) O-ring (2) O-ring (1) Socket head bolt (4)

Issued 08-2008

8011-29 6 Reference number (3): Inlet section assembly

B-B AS07001-004

1. 2. 3. 4.

Inlet housing (1) Relief valve kit (1) Plug assembly (1) Plug assembly (1)

ASM-19-07-001

5. 6. 7. 8.

O-ring (1) O-ring (1) O-ring (2) O-ring (1)

Issued 08-2008

8011-30 7 Reference number (40): Anti-drift valve assembly

AS07001-005

1. 2. 3. 4. 5. 6. 7. 8.

Body (1) Poppet (1) Plug (1) Piston (1) Spool (1) Sleeve (1) Spring (1) Spring (1)

ASM-19-07-001

9. 10. 11. 12. 13. 14. 15. 16.

O-ring (1) O-ring (1) Backup ring (1) Backup ring (1) O-ring (1) Plug assembly (1) O-ring (2) Spring seat (1)

Issued 08-2008

8011-31 8 Reference number (29): Shut-off valve assembly

AS07001-006

1. Poppet (1) 2. O-ring (1) 3. O-ring (1)

ASM-19-07-001

4. Plug (1) 5. Hexagon nut (1) 6. Set screw (1)

Issued 08-2008

8011-32

NOTES .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... 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.................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... ASM-19-07-001

Issued 08-2008

8012

Copyright ©

Section 8012 ASSEMBLY AND DISASSEMBLY OF THE ATTACHMENT CYLINDERS

CNH

Lep SM75SR8012-0EN


Copyright © 8012-2

Lep SM75SR8012-0EN

Issued 08-2008

Copyright © 8012-3

TABLE OF CONTENTS CYLINDER ............................................................................................................................................................... 4 STRUCTURAL DRAWINGS ....................................................................................................................................... 4 Boom cylinder ................................................................................................................................................... 4 Dipper cylinder (mono boom spec.) .................................................................................................................. 6 Dipper cylinder (offset boom spec.) .................................................................................................................. 8 Bucket cylinder (mono boom spec.)................................................................................................................ 10 Bucket cylinder (offset boom spec.) ................................................................................................................ 12 Offset cylinder (offset boom spec.) ................................................................................................................. 14 Blade cylinder.................................................................................................................................................. 16 Swing cylinder ................................................................................................................................................. 18 MAINTENANCE INSTRUCTIONS .............................................................................................................................. 20 Description of functions................................................................................................................................... 20 Maintenance/Inspection and Servicing ........................................................................................................... 24 Error diagnosis ................................................................................................................................................ 25 Storage standards........................................................................................................................................... 29 Instructions for disassembling and assembling............................................................................................... 30 SPECIAL JIGS FOR REPAIR ................................................................................................................................... 44 Dimensions of Tools........................................................................................................................................ 44 Handling the Jigs for Cylinder Repair.............................................................................................................. 45 Structure and features of jigs for cylinder repair ........................................................................................... 46 List of jigs ...................................................................................................................................................... 48 Handling jigs.................................................................................................................................................. 49

Lep SM75SR8012-0EN

Issued 08-2008

Copyright © 8012-4

CYLINDER 1 Structural drawings

KAV2434X-B

1 Boom cylinder CX75SR - CX80

ASM-17-24-002

Issued 08-2008

Copyright © 8012-5 No.

Part name

Q’ty

No.

Part name

Q’ty

No.

Part name

Q’ty

1

Tube

1

13

Cushion seal

2

25

Pipe

1

2

Rod

1

14

Collar

1

26

Pipe

1

3

Cylinder head

1

15

Backup ring

1

27

Plug

2

4

Bushing

1

16

Cushion seal

1

28

O-ring

4

5

Snap ring

1

17

Piston

1

29

Nipple

1

6

Buffer ring

1

18

Seal ring

1

30

O-ring

1

7

U-ring

1

19

Slide ring

2

31

Pipe holder

2

8

Wiper ring

1

20

Nut

1

32

Bolt

2

9

O-ring

2

21

Set screw

1

33

Grease nipple

1

10

Backup ring

1

22

Steel ball

1

34

Grease nipple

1

11

O-ring

1

23

Pin bushing

2

12

Holder

1

24

Wiper ring

4

Weight: 103 kg

ASM-17-24-002

Issued 08-2008

Copyright © 8012-6

HOLE (1)

KAV2436X-B

2 Dipper cylinder (mono boom spec.) CX75SR - CX80

ASM-17-24-002

Issued 08-2008


Part name

Q’ty

No.

Part name

Q’ty

No.

Part name

Q’ty

1

Tube

1

14

Spacer

1

27

Pin bushing

1

2

Rod

1

15

Collar

1

28

Wiper ring

2

3

Cylinder head

1

16

Backup ring

1

29

Pin bushing

1

4

Bushing

1

17

Cushion seal

1

30

Wiper ring

2

5

Snap ring

1

18

Piston

1

31

Nipple

1

6

Buffer ring

1

19

Seal ring

1

32

Pipe

1

7

U-ring

1

20

Slide ring

2

33

Plug

1

8

Wiper ring

1

21

Set screw

1

34

O-ring

2

9

O-ring

2

22

Steel ball

1

35

Pipe holder

1

10

Backup ring

1

23

Cushion seal

1

36

Bolt

1

11

O-ring

1

24

Pin bushing

1

37

Grease nipple

1

12

Holder

1

25

Stopper

2

13

Cushion seal

1

26

Snap ring

1

Weight: 78 kg

ASM-17-24-002

Issued 08-2008

Copyright © 8012-8

KAV2438X-B

3 Dipper cylinder (offset boom spec.) CX75SR

ASM-17-24-002

Issued 08-2008


Part name

Q’ty

No.

Part name

Q’ty

No.

Part name

Q’ty

1

Tube

1

14

Spacer

1

27

Snap ring

1

2

Rod

1

15

Collar

1

28

Pin bushing

2

3

Cylinder head

1

16

Backup ring

1

29

Wiper ring

4

4

Bushing

1

17

Lock washer

1

30

Pin bushing

1

5

Snap ring

1

18

Cushion seal

1

31

Pipe

1

6

Buffer ring

1

19

Piston

1

32

Pipe

1

7

U-ring

1

20

Seal ring

1

33

Plug

2

8

Wiper ring

1

21

Slide ring

2

34

O-ring

4

9

O-ring

2

22

Set screw

1

35

Nipple

1

10

Backup ring

1

23

Steel ball

1

36

O-ring

1

11

O-ring

1

24

Cushion ring

1

37

Pipe holder

2

12

Holder

1

25

Cushion seal

1

38

Bolt

2

13

Cushion seal

1

26

Stopper

2

39

Grease nipple

1

Weight: 81 kg

ASM-17-24-002

Issued 08-2008


KAV2440X-B

4 Bucket cylinder (mono boom spec.) CX75SR - CX80

ASM-17-24-002

Issued 08-2008


Part name

Q’ty

No.

Part name

Q’ty

No.

Part name

Q’ty

1

Tube

1

11

O-ring

1

21

Pipe

1

2

Rod

1

12

Piston

1

22

O-ring

1

3

Cylinder head

1

13

Seal ring

1

23

Bolt

4

4

Bushing

1

14

Slide ring

2

24

Pipe

1

5

Snap ring

1

15

Set screw

1

25

Plug

1

6

Buffer ring

1

16

Steel ball

1

26

O-ring

2

7

U-ring

1

17

Pin bushing

1

27

Pipe holder

2

8

Wiper ring

1

18

Wiper ring

1

28

Bolt

2

9

O-ring

1

19

Pin bushing

1

29

Grease nipple

2

10

Backup ring

1

20

Wiper ring

2

Weight: 61 kg

ASM-17-24-002

Issued 08-2008


KAV2441X-B

5 Bucket cylinder (offset boom spec.) CX75SR

ASM-17-24-002

Issued 08-2008


Part name

Q’ty

No.

Part name

Q’ty

No.

Part name

Q’ty

1

Tube

1

11

O-ring

1

21

Pipe

1

2

Rod

1

12

Piston

1

22

Plug

1

3

Cylinder head

1

13

Seal ring

1

23

O-ring

2

4

Bushing

1

14

Slide ring

2

24

Nipple

1

5

Snap ring

1

15

Set screw

1

25

O-ring

1

6

Buffer ring

1

16

Steel ball

1

26

Pipe holder

1

7

U-ring

1

17

Pin bushing

1

27

Bolt

1

8

Wiper ring

1

18

Wiper ring

1

28

Grease nipple

1

9

O-ring

1

19

Pin bushing

1

29

Grease nipple

1

10

Backup ring

1

20

Wiper ring

2

Weight: 61 kg

ASM-17-24-002

Issued 08-2008


KAV2442X-B

6 Offset cylinder (offset boom spec.) CX75SR

ASM-17-24-002

Issued 08-2008


Part name

Q’ty

No.

Part name

Q’ty

No.

Part name

Q’ty

1

Tube

1

11

O-ring

1

21

O-ring

2

2

Rod

1

12

Piston

1

22

Nipple

1

3

Cylinder head

1

13

Seal ring

1

23

O-ring

1

4

Bushing

1

14

O-ring

2

24

Pipe holder

1

5

Snap ring

1

15

Set screw

1

25

Bolt

1

6

Buffer ring

1

16

Steel ball

1

26

Grease nipple

2

7

U-ring

1

17

Pin bushing

2

8

Wiper ring

1

18

Wiper ring

4

9

O-ring

1

19

Pipe

1

10

Backup ring

1

20

Plug

1

Weight: 41 kg

ASM-17-24-002

Issued 08-2008


KAV2085X-B

7 Blade cylinder CX75SR - CX80

ASM-17-24-002

Issued 08-2008


Part name

Q’ty

No.

Part name

Q’ty

No.

Part name

Q’ty

1

Tube

1

11

Seal ring

1

21

Pipe holder

1

2

Rod

1

12

Slide ring

2

22

Bolt

1

3

Cylinder head

1

13

Set screw

1

23

Grease nipple

2

4

Bushing

1

14

Steel ball

1

5

Snap ring

1

15

Pin bushing

1

6

Buffer ring

1

16

Wiper ring

4

7

U-ring

1

17

Pin bushing

1

8

Backup ring

1

18

Pipe

1

9

O-ring

1

19

Plug

1

10

Piston

1

20

O-ring

2

Weight: 34 kg

ASM-17-24-002

Issued 08-2008

ASM-17-24-002

INSIDE DETAIL FREE SCALE

HOLE(1)

TYPE-A PT1/8

LOCATION OF THE SLIT IS SHOWN IN THE DRAWING

2-PT1/8(WITH PLASTIC CAP)

STROKE 640

CUSHION STROKE

TIGHTENING TORQUE 1830 Nm (M45 x 3 HEX WAF 70)

CUSHION STROKE

S SECTION DETAIL (NOT SCALED PROPORTIONALLY)

TIGHTENING TORQUE 17.2 ± 0.9 Nm (2-M8 x 1.25) CLOSED 1085

FROM BOTTOM PIN CENTER LOCATION OF THE SLIT IS SHOWN IN THE DRAWING

TIGHTENING TORQUE 31.5 ± 5.88 Nm (M10 x 1.5)CAULKING(2 PLACES)

MANUFACTURING No. STAMPING POSITION

TIGHTENING TORQUE 669 Nm(M102 x 2) APPLY THREE BOND #1901 TO THE THREADS

PS1/8 WITH PLASTIC CAP

PIPE ATTACHMENT (2 PLACES)

KAV2787P1C01

SECTION Y-Y

PORT DETAIL (2 PLACES)

TIGHTENING TORQUE 76.4 ± 3.8 Nm (M16 x 1.5)

THE SPACER HAS AN IDENTIFICATION GROOVE ON ITS CIRCUMFERENCE

WEIGHT: 56 kg

Copyright ©

8012-18

8 Swing cylinder CX80

Issued 08-2008


Part name

Q’ty

No.

Part name

Q’ty

No.

Part name

Q’ty

1

Tube

1

13

Cushion seal

1

25

Stopper

2

2

Rod

1

14

Spacer

1

26

Snap ring

1

3

Cylinder head

1

15

Collar

1

27

Pin bushing

2

4

Bushing

1

16

Backup ring

1

28

Wiper ring

4

5

Snap ring

1

17

Cushion seal

1

29

Pipe

1

6

Buffer ring

1

18

Piston

1

30

Pipe

1

7

U-ring

1

19

Seal ring

1

31

Plug

1

8

Wiper ring

1

20

Slide ring

2

32

O-ring

1

9

O-ring

2

21

Set screw

1

33

Pipe holder

1

10

Backup ring

1

22

Steel ball

1

34

Bolt

2

11

O-ring

1

23

Cushion seal

1

35

Grease nipple

1

12

Holder

1

24

Pin bushing

1

Weight: 56 kg

ASM-17-24-002

Issued 08-2008


2 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 direction between extension and retraction by way of lever operation on the hydraulic oil direction switch-over valve. This larger force, linear movement, and operational direction switching over are the basic functions. 2) Function by section

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

C A

B

AQ24002-001

A: Black, B: Green, C: Split Bushing (4) The bushing is press fitted into the inner face of the cylinder head and is in contact with the piston rod. It reduces eccentricity, which adversely affects the seal performance, by sharing lateral load applied on the cylinder together with the slide ring located on the outer circumference of the piston, performing high-bearing linear motion against the piston rod, as well as supporting one end of the piston rod.

ASM-17-24-002

Issued 08-2008

Copyright © 8012-21 Buffer ring (6) The buffer ring is composed of a slide ring and a square ring and is located between the U-ring and bushing. It prolongs the life of the U-ring, which is the main seal, by relieving high pressure with the auxiliary seal which is directly in contact with the high pressure oil in the cylinder, and reducing the load acting on the U-ring. U-ring (7) The U-ring is located between the wiper ring and the buffer ring. The U-ring seals the annular space formed between the piston rod and cylinder head against the pressure oil between the U-ring and the backup ring. It also forms suitable oil films on the piston rod to prevent rust. Wiper ring (9) The wiper ring is located at the opening end where the piston rod enters into and exits from the cylinder. It prevents dust and water from entering into the rod seal section of the U-ring and the buffer ring in the cylinder from the outside. It also scrapes off mud attached on the surfaces of piston rod through piston rod movements. 2) Piston assembly The piston assembly has the function of transmitting the propulsion of the cylinder. A seal ring (16) is mounted on the center of the piston (15) to prevent the flow of pressurized oil from either the left or right chamber to the other chamber. There are slide rings (18) and (19) mounted at each end of the seal ring. They have the function of a bearing to receive the cylinder lateral load. 2

1

13

14

15

16

17

18

19

20 21

25

23

22

24

Use caution with the direction of the cut surfaces during installation Face "the split" to the piston side. RM15001-070

1. 2. 13. 14. 15. 16. 17. 18.

Cylinder tube Piston rod Cushion ring Cushion seal Piston Seal ring Backup ring Slide ring

ASM-17-24-002

19. 20. 21. 22. 23. 24. 25.

Slide ring Locking screw Steel ball Cushion ring Cushion seal Stopper Snap ring

Issued 08-2008

Copyright © 8012-22 For some cylinder sizes, the piston (15) and nut (21) are separate.

2

1

13

14

15

16

17

18

19

20

21

22 23

27

25

24

26

Use caution with the direction of the cut surfaces during installation Face "the split" to the piston side. RM15001-071

1. 2. 13. 14. 15. 16. 17. 18. 19.

Cylinder tube Piston rod Cushion ring Cushion seal Piston Seal ring Backup ring Slide ring Slide ring

20. 21. 22. 23. 24. 25. 26. 27.

Shim Nut Locking screw Steel ball Cushion ring Cushion seal Stopper Snap ring

Example of parts numbers for separated piston and nut. Seal ring (16) and backup ring (17) The seal ring (16) is positioned at the center of the piston (15) and uses the tension force of the O-ring to seal the ring-shaped gap between the piston and the cylinder tube (1) and form chambers with a high-pressure side and a low-pressure side with the piston as the boundary. The backup ring (17) has the function of suppressing extrusion of the seal ring into the gap between the piston and the cylinder tube when the pressure operates and of improving durability. Slide ring (18) and (19) Slide rings are positioned at both ends of the seal ring (16) and contact the inside surface of the cylinder tube (1). Together with the bushing (4) positioned on the inside surface of the cylinder head (3), the slide ring divides the lateral load applied to the cylinder and moves linearly relative to the inside surface of the cylinder tube. Furthermore, it supports one end of the piston rod (2) and has the functions of minimizing eccentricity, which has a negative impact on the sealing, and buries and captures any impurities trapped between the cylinder tube and the slide rings (18) and (19). Cushion ring (13) and (24) When the cylinder is fully extended, the cylinder head (3) and the cushion ring (13) fit together. When it is fully retracted, the cylinder bottom and the cushion ring fit together. In both cases, this forms a ring-shaped gap and squeezes the oil to reduce the cylinder collision speed at full extension or full retraction and thus soften the impact.

ASM-17-24-002

Issued 08-2008

Copyright © 8012-23 3) Pipes (28) and (29) A pair of pipes are located on each port on the extension and retraction side on the cylinder tubes (1). The pipes supply and drain high-pressure oil from the flexible hose connection end to the cylinder tube port.

000-7-05-02-19c

ASM-17-24-002

Issued 08-2008

Copyright © 8012-24 2 Maintenance/Inspection and Servicing To gain full functions of hydraulic cylinder for a long time, conduct periodic inspections and servicing based on the inspection table below. Repair faulty sections as soon as possible. NOTE: When conducting routine inspections and servicing, the first priority should be placed on the operatorÕs safety. Conduct the operation using common knowledge and expertise. Locations for inspection / servicing

Appearance

Operation

Hydraulic oil

Fitting section onto the main machine

Inspecting and servicing points

Daily

Is cylinder clean (especially sliding part of the rod)?

O

Is there any oil leakage from the piping fitting part? O

Is movement smooth? Any abnormal noises?

O

Is response good?

O

Is there any oil leakage from the sliding parts?

O

Is there any internal leakage?

ASM-17-24-002

Notes

O

Is working pressure normal?

O

Is set pressure on over load relief valve normal?

O

Is the hydraulic oil dirty or deteriorated?

O

Is the hydraulic oil changed regularly?

O

Are filters changed regularly?

O

Is there enough grease on the pins?

O

Do the pins make noise or seize up?

O

Is there any looseness or wear on the pins?

O

Are the pin seals normal?

O O

Retighten fitting screws.

O

Is there any wear on sliding parts?

O

Are there any scratches or dents on the sliding parts?

O

Is plating scraped off on the sliding part?

O

Are any sliding parts bent?

Cylinder tubes (including piping)

Annually

O

Is there any paint peeling, scaling or rust?

Are there any loose or missing screws?

Piston rod

Monthly

If the sliding part of the rod is exposed for a long time, apply corrosion inhibitor.

O

Are there any cracks on or damage to welded parts?

O

Are any bolts, nuts (screws) loose?

O

Retighten bolts and nuts (screws).

O

Are there any cracks on or damage to welded parts?

O

Are there any cavity or dents on the tube?

O

Issued 08-2008

Copyright © 8012-25 3 Error diagnosis 1) Hydraulic cylinder errors and their remedy measures It is not easy to locate faulty parts. General symptoms, possible reasons and remedy measures are shown in the table below. For repairs, refer to the possible causes and remedy measures in the table. However, it is often the case that machine troubles occur because not only one part but many other relating parts have problems. Measures other than ones shown in the table may be required. Item

Symptom

1

Oil leakage on the sliding section of piston rod (for assessment values, refer to 5-(4) Inspections after assembly).

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

Scratches and rust caught by claws on the sliding surface

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

Plating is flaking

1) Re-plate or replace piston rod. 2) At this time, check seals and piston rod bearing materials, and if damage is found, replace them.

Foreign substances engaged in the inside and outside surfaces

1) Remove foreign substances. 2) If a packing is damaged, replace it.

Piston rod

1

Oil leakage on piston rod sliding section

Scratches on inside and outside Rod packing (buffer ring and surfaces U-ring) Lips and grooves are locally carbonized (burned).

ASM-17-24-002

Preventive/remedy measures

Replace 1) Regarded as burning damage by air adiabatic compression caused by remaining air in the cylinder. 2) Perform initial operation at low pressure and low speed to bleed air fully after changing packing.

Issued 08-2008

Copyright © 8012-26 Item

Symptom

Related parts

Rod packing (buffer ring and U-ring)

Backup ring

1

Oil leakage on piston rod sliding section

Wiper ring

Bearing material (Bushing)

Cylinder head

2

Oil leakage from cylinder head fitting section

ASM-17-24-002

O-ring

Error item


Packing has lost rubber elasticity and is crumbling. The whole lip is also missing.

1) Replace. 2) The life of the packing or hydraulic oil deterioration or high temperature may e the cause. 1. Change hydraulic oil. 2. Check hydraulic oil temperature. (The oil temperature should be 80 °C or less.) 3. Check for uneven hot temperatures.

Heel part of the packing. Too much extrusion.

1) Replace. 2) Abnormal high pressure may act on the packing. 1. Check the pressure when starting operation. 2. Abnormality in the buffer ring if the buffer ring is attached. Inspect buffer rings.

Visible distortion

1) Change rod packings together, as a general rule. (Buffer rings should be replaced at the same time if attached). 2) Abnormally high pressure may have caused this. In this case, check it by following the same steps described above for the packing heel extrusion.

Foreign substances engaged in the lip

Remove foreign substances.

The lip is damaged. Other abnormal damages

Replace.

Extreme wear, the clearance with piston rod exceeds the allowable maximum value (see 5-3. Maintenance reference)

Replace.

Significant damage in sliding surfaces

1) Replace. 2) Inspect the piston rod.

Scratches or rust in seal fitting area.

1) Remove scratches and rust with an oil stone. 2) If repair is not possible, replace the cylinder head

Foreign substances on the inside and outside surfaces Damaged O-ring

1) Remove foreign substances. 2) If O-ring is damaged, replace it. 3) Inspect the tube inside: If scratches and rust are found, smooth the surfaces with oilstone. 4) Check O-ring grooves in the cylinder head: Same as above 5) Check backup rings:If distortion or extrusion is found, replace it. Change O-rings after confirming items above. Issued 08-2008


Symptom

Related parts Backup ring

2

4

Bad operation 4-1 Does not move smoothly

1) Disassemble cylinder head to check O-rings and backup rings. If damage is found, replace it. 2) Check tube and cylinder head threaded sections to ensure that there is no damage. If damage is found, replace it. 3) Upon completion of inspection, fasten with specified tightening torque. Refer to Tightening torque.

Bolt

Looseness, extension and breakage

Replace all bolts and fasten them with specified tightening torque.

Abnormal swelling

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

Cracks on welded section

Replace with new ones. WARNING: Cracks will progress and end up with breakage. - Breakage is a very dangerous condition. - If cracks are found, immediately stop the operation and replace the parts. - No effect can be gained if additional welding is performed on cracked surfaces.

Cylinder tube pipe (hollow piston rod)

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

Replace with new ones. Check seals and sliding materials also because they may be damaged. If abnormality is found, replace.

Cylinder tubes

Replace with new ones. Same as above described, check seals and sliding materials.

Dents

Abnormal wear and damage on the sliding parts Piston rod, cylinder tubes, Foreign sustances sliding materals engaged in the piston and cylinder head sliding parts

ASM-17-24-002

Change together with O-ring.

Looseness

Cylinder tubes

3

Distortion and extrusion.


Cylinder head Oil leakage from cylinder head fitting section

Oil leakage from welded section between pipe and cylinder tube

Error item

1) Replace with new ones. Same as above described, check seals and sliding materials. 2) Remove foreign substances. Same as above described, check seals and sliding materials.

Issued 08-2008


Symptom

4-2 Internal oil leakage makes the piston rod extend or retract or fall abnormally while operating or can not give specified speed output.

Related parts

Error item


Piston seal

Damage such as scratches and wear is found.

Cylinder tubes

Scratches and rust on the inside surface.

Piston nut

Loose tightening.

Fasten with specified tightening torque. Refer to Tightening torque.

Valves

Leakage from valves.

Check the valve leakage volume and repair if necessary.

Replace with a new one. Also check the cylinder’s inner face. 1) Remove scratches and rust by honing or with oilstone to smooth the surfaces. If scratches are too big to repair, replace cylinder tubes with new ones. 2) Replace piston seals with new ones.

WARNING: Hydraulic oil tends to expand and shrink according to changes in temperature and pressure. This also causes cylinders to extend and retract; therefore, we sometimes see this as internal oil leakage. Check internal oil leakage under a given pressure condition.

4-3 Operation is not stable.

Air

Air remains in the cylinder.

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

4-4 Strong impact when switching over between extension and retraction.

Pin bushing Pin

Too much clearance between the fitting section and pin bushing.

Measure the dimensions of pin and pin bushing, replace the parts that exceed the measured dimensions.

Lubrication

Lack of lubrication.

Lubricate.

Pin bushing Pin

Scuffing on fitting surfaces.

Replace with a new one and lubricate.

4

4-5 Cylinder sliding operation makes noise.

WARNING: Hydraulic oil tends to expand and shrink according to changes in temperature and pressure. This also causes cylinders to extend and retract; therefore, we sometimes see this as internal oil leakage. Check internal oil leakage under given temperature and pressure conditions.

ASM-17-24-002

Issued 08-2008

Copyright © 8012-29 4 Storage standards We take all possible measures at the time of shipping hydraulic cylinders. However, in order to avoid trouble when storing them, please handle them following the precautions below. 1) Storing one unit only (as a general rule, store indoors) Avoid a place with high temperature and high humidity or a place where corrosive gas or liquid is stored. Store the unit off the floor. To prevent condensation due to temperature difference, we conduct inspections by using test oil with a given volume of volatile corrosion inhibitor, retract the piston rod using super dry air (dew point 35 °C), put caps when shipping. Therefore, do not leave a cylinder with the cap removed or drain the remaining oil from the cylinder without clear intention. Storage for more than 1 months

Storage for more than 6 months (3 months for single-acting cylinder)

Storage for more than one year

Clean dust from the cylinder and apply corrosion inhibitor to flange section, piston rod and other locations that rust easily.

1. Using clean hydraulic oil, let the cylinder reciprocate to introduce corrosion inhibitor into the cylinder following the steps described in the left column for 1 month storage.

1. As packing may be deteriorated, it is desired to disassemble and inspect, and replace the packing. Also, check rust conditions on the cylinder inner walls.

2. If the cylinder does not operate, add corrosion inhibitor only.

2. If cylinders, which have been stored for a long time, are used as they are, there is possibility of oil leakage because of temporary poor sealing conformity.

3. Care is needed to avoid falling, collision, dislodgment and dents while storing. 2) At the time of installing devices 1.

Operate cylinder at least once every 1 months.

2.

Keep the piston rod in its retracted position, avoid exposure to outside air and apply corrosion inhibitor or grease to the exposed parts at least once a month.

3.

Careful handling is necessary to avoid damage to piston rods.

4.

If cylinders are placed under conditions where they are exposed to salty wind (e.g. during exports), always apply corrosion inhibitor to piston rods and protect them as much as possible with polyethylene or V.C.I paper.

5.

Solutions such as corrosion inhibitors may have adverse effects on sealing materials. Therefore, careful selection and handling is required to avoid getting oil on dust seals. (Recommended corrosion inhibitors are listed below.)

ASM-17-24-002

Issued 08-2008

Copyright © 8012-30 5 Instructions for disassembling and assembling 1) Preparation Before starting the disassembly, prepare the following items:

1) Prepare a workbench 2) Choose and prepare a stable and strongly built workbench large enough to arrange and keep parts and perform jobs. 2) General precautions for work

1) Before disassembly, fully rinse soil and dust attached to the cylinder outside walls. 2) As each part is a precision component, handle parts carefully and do not drop them or allow them to hit each other. 3) Do not attempt to hit or pry parts forcedly because they are tightly fitted. Take time and carry out the operation carefully in order to avoid causing burrs or damage resulting in inability to reassemble a part, oil leakage or lower efficiency. 4) If components are left disassembled or half-disassembled, the parts may rust because of moisture and dirt. Rust prevention and dirt-proofing should be considered if the operation is suspended for unavoidable reasons. 3) Maintenance reference For sliding parts and sealing parts, replace them following the items below: 1) Bushing

When a whole quarter of the circumference has worn and turned reddish copper color

2) Seals and slide rings

Replace with new ones when disassembling cylinders

3) Pin bushing

When serious scuffing has occurred

ASM-17-24-002

Issued 08-2008

Copyright © 8012-31 4) Inspection after assembly Dimension inspection

Check the fully retracted length and stroke as instructed on the diagram.

Pressure withstand inspection

Check for looseness, permanent deformation, and external leaks when the test pressure instructed on the diagram is applied to each stroke end for at least 3 min. Check the amount of oil leak at the rod section. Judgment value for rod section oil leak Move the piston rod back and forth 20 times with the oil at a temperature from 20 °C to 40 °C, and then judge by the state of the oil ring formed on the rod surface. If the oil ring is in a broken down A state, this is judged to be trouble. See "5. Trouble Diagnostics" for information on how to solve this. Oil ring

External leak inspection 2 mm

A

B

Not acceptable

1 mm

C

D

E F G

Acceptable

R

Oil leak unit: ml/10 min.

Internal leak inspection

ASM-17-24-002

Interior diameter mm

Oil leak amount

160

10.0

4.0

180

12.6

125

5.6

200

15.6

140

6.0

220

20.0

250

22.0



Oil leak amount

32

0.4

40

0.6

100

50

1.0

63

1.6

80

2.3

Oil leak amount

Issued 08-2008

Copyright © 8012-32 5) Required tools

1) General tools 1 9

2 6

2 5 6 7

4

2 6

1 3 9

2 6

4 8 RM15001-080

Tool name Screwdriver (flathead screwdriver) (1)

RM15001-081

Hexagon wrench (1 set)

RM15001-082

Vise (1)

RM15001-083

Wrench (for piston nuts) (1 set)

RM15001-084

Punch (1)

RM15001-085

Torque wrench (1 set)

RM15001-086

Hammer (Plastic hammer) (1)

RM15001-087

Monkey wrench (1)

RM15001-088

Scoop (1 set)

RM15001-089

ASM-17-24-002

Issued 08-2008


2) Special jig Cylinder assembly requires the following special jigs. ASM-17-24-002

Issued 08-2008

Copyright © 8012-34 For bushing removal and press fitting

RM15001-090

For wiper ring press fitting

RM15001-091

Seal ring insertion jig

RM15001-092

Seal ring calibration jig

RM15001-130

For cylinder head insertion

RM15001-093

For piston insertion

RM15001-094

Consult with our company about jigs.

ASM-17-24-002

Issued 08-2008

Copyright © 8012-35 6) Instructions for disassembling

1) Drain oil. 2) Remove piping. 3) Secure cylinder. Secure the cylinder in a vertical or horizontal position. Vertical securing facilitates the disassembly and reassembly. When securing it, stop rotations and axial movement using the bottom pin holes.

Band for piping (not necessary to remove unless replacement is needed

000-7-05-02-19z1

4) Loosen and remove cylinder head tightening bolts using hexagonal bar spanner. Inserting a pipe as shown below facilitates the operation.

1.5 m

5) Pull out the piston rod. 1. Ensure that the piping ports are open. 2. Place an oil sump at the port on the retraction side (cylinder head). 3. Pull the cylinder head slowly with the piston head fully pulled. AQ24002-050

4. Pull out the cylinder head together with the piston rod and place them on the sleeper. WARNING: When carrying out this operation in a vertical position, pay special attention to the following: When the piston rod is first pulled out with all the screws on the cylinder head removed, pulling the cylinder head out from the tube makes a space between the piston rod and piston. In this situation, it is possible that when the cylinder head reaches a given height, it may slide down suddenly, causing injury to the operator. Always keep the cylinder head in contact with the piston while carrying out this operation.

DANGER! It may fall

When performing the operation in a vertical position AQ24002-051

ASM-17-24-002

Issued 08-2008

Copyright © 8012-36 WARNING: When the piston rod is pulled out in a horizontal position, it may drop immediately after it is pulled out, causing damage to the parts. Pull out the rod using a sleeper to hold it in a horizontal position.

When performing th operation in a horizontal leval position

DANGER! It may fall

000-7-05-02-19ab

6) Secure the piston rod. 1. Stop rotations using the rod head width across flats or pin holes.

Drill

Steel ball 000-7-05-02-19ac

7) Remove piston nuts. Piston nut

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

Jack

3. Remove piston nuts. The piston nuts are tightened to the torque listed in the assembly drawing.To loosen the piston nut, about 1.5 times as much torque is required. If larger torque is necessary, prepare a powered wrench that utilizes a hydraulic jack or a hydraulic cylinder.

Hydraulic cylinder 000-7-05-02-19ad

8) Remove piston, cushion bearing, and cylinder head in this order. Cylinder head Cushion bearing

Cushion seal

Piston 000-7-05-02-19ae

ASM-17-24-002

Issued 08-2008

Copyright © 8012-37 9) Disassembly on the retraction side (arm cylinder).

1

4 5

Flattening

Screw

3 6

2

A

000-7-05-02-19af

Hit with plastic hammer while holding one side

1. Remove piston nut (1). With the nut attached, the disassembly cannot proceed. 2. Remove snap ring (2). Remove it by softly hitting with a plastic hammer while being careful to avoid damage to piston rod (3) and cushion bearing (4). 3. Slide cushion bearing to the threaded side of the piston rod, and the stopper (5) (two-piece) will come off. 4. Remove cushion bearing. 5. The cushion seal (6) has a one slit (A). Use it to enlarge the opening. Remove piston seal. 1. The slide ring (7) and backup ring (8) can be easily removed manually. 2. Cut and remove the seal ring (9) by placing a screwdriver on the ring as shown in the right figure and hitting it with a hammer.

9

7

B D C

3. Pull out and remove O-ring (10) with a spatula. 4. Do not reuse the removed seal parts. B: Piston

10 8 000-7-05-02-19ag

C: Vise D: Hardwood

ASM-17-24-002

Issued 08-2008

Copyright © 8012-38 10) Disassembling buffer ring (11) 1. Buffer rings (11) (Teflon seal) is fitted in the inner grooves of the cylinder head. When removing this seal, pierce it with a sharp tool and lift it up, then insert a spatula and remove it. 2. Do not reuse the removed seals. 11) Disassembling U-rings, backup rings and wiper ring. 17, 18 15

14

11

13

16

12

000-7-05-02-19ah

1. Remove U-ring (12) and back-up ring (13, 18) using screwdriver or equivalent. 2. Wiper rings(14) are press fitted. Pierce with a tool such as screwdriver on the rubber, hit the tool and remove it. 3. Do not reuse the removed seal parts. 12) Disassembling DU bushing (15).

Push with press

1. Remove the snap ring (16) by prying with a screwdriver from the cylinder head (19). 2. Push out the DU bushing with a press using a jig (E). 13) Cleaning and Storage

E

15

1. Apply hydraulic oil to the removed parts after cleaning with white kerosene. Cover and store them. 2. If components are left disassembled, they may not operate fully as expected after reassembly because of rusting and dust. 000-7-05-02-19ai

7) Instructions for assembly WARNING: Careful handling is needed when reassembling because peeled paint from parts may enter into the cylinder.

1) Changing seals 1. Change all seals when the cylinder is disassembled. 2. O-ring Before fitting backup rings (18) and O-rings (17), clean the fitting grooves fully. Foreign substances in the grooves may cause oil leakage. Pay attention to the positions of backup rings. Apply grease or hydraulic oil before fitting to the backup ring and O-ring to make them move smoothly. If they do not move smoothly, the O-ring will distort when being installed and cause oil leakage.

ASM-17-24-002

18 17 Pressure side

19 000-7-05-02-19aj

Issued 08-2008

Copyright © 8012-39 2) Cylinder head 1. Press fit the DU bushing (15) with press using a jig (F). 2. Press fit the wiper ring (14) with press using a jig (G).

Press

(

Press holder

CM

3. Fit backup ring (13) and U-ring (12) in the Uring groove (H) in this order. Ensure that there is no remaining permanent deformation such as creases after fitting.

14 G H

Push with press

000-7-05-02-19al

3) Buffer ring (11) assembly 1. Install the backup ring (a) and slide ring (b) in this order by forming U-shape (d) with the fingers, placing them into the groove and pushing out them toward the outer circumference after fitting the square ring (c) in the groove. If the rings are shaped with too small a radius, creases will remain after fitting. Therefore, use a radius of 6 mm or more to make a curve. Ensure that there is no crease after fitting. Pay attention to the fitting directions of seals. Reversing them will cause high pressure between the seal and U-ring and lead to deformation on the cylinder head.

a, b

d 000-7-05-02-19am

2. Fit DU bushing locking snap ring (16). 11

c

a

b 16 AQ24002-052

ASM-17-24-002

Issued 08-2008

Copyright © 8012-40 4) Piston 1. Place the piston (B) on the press and install a seal ring (9) using a jig as shown in the figure to the right. (Pre-fit O-ring (10) and back up ring (9) to one side.) 2. Immediately after fitting seal ring and backup ring on the other side, correct the seal ring using a correction jig so that it does not remain expanded. (This must be strictly observed.) Reinforcing plate Push with press

Push with press

8

Jig (A) (nylon pipe)

Correction jig (C)

Jig (B)

B

9

10

8

AQ24002-053

5) Assembling piston rod 1. Secure the piston rod. 2. Engage the cylinder head. Care must be taken to confirm that the lips of the wiper ring and the U-ring are not engaged with the stepped part.

Jig for assembling use

000-7-05-02-19ap

3. Engage cushion seal (6), cushion bearing (4) and piston (B). (Cushion seals are not required for bucket cylinders) Then, fit shim and fasten the piston nut. (Direct the “slit” (A) on the cushion seal toward the piston side.)

B 4

1a 1

6

A 000-7-05-02-19aq

ASM-17-24-002

Issued 08-2008

Copyright © 8012-41 4. Tighten piston nuts using torque listed in the assembly drawing. Pay attention to a lack of tightening torque because it may cause internal leakage, loose nuts, and screw breakage.

J

K

5. After tightening the piston nut, put in the steel ball (20) and tighten set screw (21) using torque listed in the assembly drawing. Crimp (J) with a punch (K) at two places on the outer circumference.

21

20 000-7-05-02-19ar

6) Installing cushion bearing on the retraction side 1. Install the cushion bearing (4) before fitting the piston nut (1). With nut attached, the installation cannot proceed. 2. Insert the cushion seal (6) into the groove by facing its slit (A) processed side toward the threaded side. 3. Install the cushion bearing by facing the flattened part as shown in the drawing. 4. Insert stopper (5) into the groove. 5. Push the cushion bearing up to the stopper fully and knock in the snap spring (2). Softly hit it with a plastic hammer while paying attention to avoid damage to the rod (3) and cushion bearing. WARNING: Be aware that installing directions of cushion seals and cushion rings are different. Make sure that the cushion ring moves smoothly up/down and right/left after fitting snap rings.

1

4 5

3 6

2

A

AQ24002-054

ASM-17-24-002

Issued 08-2008

Copyright © 8012-42 7) Insert the piston rod into the tube. Jigs, nylon type

1. Secure the tube vertically or horizontally. Insert the piston rod into the tube. When securing vertically, piston rod enters into the tube by the act of its self-weight. When securing horizontally, push in using lever hoist or forklift.

Slide rings

2. Careful handling is needed to prevent the slide ring from dropping when the piston enters the tube.

000-7-05-02-19at

8) Installing cylinder head 1. Align the cylinder head according to the assembly drawing and set the tightening bolts by specified torque in the order shown in the drawing after fastening them alternatively. The example in the diagram has 8 bolts, but this number will vary depending on the cylinder type.The tightening method is fundamentally the same. Depending on the cylinder type, the cylinder head may be threaded or the cylinder may screw into a tube.

000-7-05-02-19au

9) Fitting piping 1. Ensure that the O-rings are placed correctly in the grooves. 2. First, fit the bolts for port sections. 3. Tighten the bolts using torque listed in the assembly drawing. 4. Tighten the band for piping using torque listed in the assembly drawing so that there is no gap. Tighten the bolt

Gap closed

Gap closed Band for piping

Be careful of O-rings 000-7-05-02-19av

ASM-17-24-002

Issued 08-2008

Copyright © 8012-43 8) Trial run

1) After fitting the cylinder on the machine, move slowly more than 8 times at the full stroke by operating the switch-over valve. The inside of the cylinder will be filled with oil. Quick and sudden movement at the initial stage can cause aeration by the hydraulic oil. 2) If air bleeder is attached (boom cylinder), apply pressure to bleed by making its air bleeding side the pressured side (return oil side). 3) Lubricate pins on both ends. 9) Use limits Wear limits on piston rod outside surfaces Nominal diameter (mm)

Minimum outer diameter (mm)

Measures

50 to 80

-0.023

Replacement or re-plating

85 to 120

-0.027

Replacement or re-plating

Wear limits on rod bushing inside surfaces Nominal diameter (mm)

Standard inner diameter (mm)

Maximum inner diameter (mm)

Measures

55 to 75

+0.06 to +0.19

+0.30

Replacement bushing

80 to 120

+0.06 to +0.195

+0.30

Replacement bushing

Wear limits of piston slide ring thickness Nominal diameter (mm)

Standard thickness (mm)

Maximum thickness (mm)

Measures

95 to 160

2.42 to 2.48

2.37

Replacement slide ring

165 to 250

2.92 to 2.98

2.87

Replacement slide ring

ASM-17-24-002

Issued 08-2008


3 Special jigs for repair 1 Dimensions of Tools Wrench for piston nuts

AQ24002-002

Unit: mm Piston nut

Wrench size

Nominal diameter

Width across flats

H

D

J

B

T

E

R1

R2

M42

65 +0 -1.2

65 +0.8 -0.3

125

350

40

20

20

50

20

M45

70 +0 -1.2

70 +0.8 -0.3

130

350

40

20

20

50

20

M48

75 +0 -1.2

75 +0.8 -0.3

140

350

40

20

20

50

20

M52

80 +0 -1.2

80 +0.8 -0.3

150

350

40

20

20

50

20

M55

85 +0 -1.4

85 +0.8 -0.3

160

350

40

20

20

50

20

M58

85 +0 -1.4

85 +0.8 -0.3

160

350

40

20

20

50

20

M62

90 +0 -1.4

90 +0.8 -0.3

160

350

40

20

20

50

20

M65

95 +0 -1.4

95 +0.8 -0.3

170

350

40

20

20

50

20

M70

100 +0 -1.4

100 +0.8 -0.3

180

400

50

25

25

50

25

M80

115 +0 -1.4

115 +0.8 -0.3

200

400

50

25

25

50

25

M85

120 +0 -1.2

120 +0.8 -0.3

220

400

50

25

25

50

25

M95

1355 +0 -1.2

135 +0.8 -0.3

245

400

60

30

30

50

30

M105

150 +0 -1.2

150 +0.8 -0.3

270

400

60

30

30

50

30

M110

155 +0 -1.2

155 +0.8 -0.3

280

400

60

30

30

50

30

WARNING: Use wrenches of S45C steel with the hardness ranging from HB201 to 269.

ASM-17-24-002

Issued 08-2008

Copyright © 8012-45 2 Handling the Jigs for Cylinder Repair

Arm cylinder

Boom cylinder

Bucket cylinder

AQ24002-003

1: Jigs for press fitting wiper ring 2: Jigs for extraction bushings 3: Jigs for press fitting bushings 4: Jigs for press fitting wiper ring 5: Jigs for guiding cylinder head insertion

ASM-17-24-002

Issued 08-2008

Copyright © 8012-46 1 Structure and features of jigs for cylinder repair 1) Jigs for insertion and correction of seal rings

1) Structure of jigs Item number KHV0530

Item name

quantity

Seal ring insertion / correction jig set

1

Inner guide

1

Outer guide

1

Plate

1

Correction

1

remarks

NOTE: The item number indicates that the item is intended for seal rings with the tube diameter of 120 mm. 2) Features Although it normally requires a tremendous amount of time and effort to insert a seal ring due to its extreme hardness, the use of the jig facilitates quick, easy and secure seal ring insertion into a piston without scratching the seal ring. 2) Jigs for injection and ejection of bushings and wiper rings


Item name

quantity

remarks

Bushing and wiper ring injection / Ejection jig set

1

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

Chuck assembly

1

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

Retainer

1

Block

1

Prepare this item at each service shop.

Lever

1


Hexagon bar wrench

1


NOTE: The item number indicates that the item is intended for bushings with the rod diameter of 80 mm. 2) Features This special jigs facilitate quick, easy and secure slide fit of a cylinder head assembly to a piston rod without scratching any seals.

ASM-17-24-002

Issued 08-2008

Copyright © 8012-47 3) Jigs for insertion of cylinder heads


Item name Jigs for insertion of cylinder heads

quantity

remarks

1

NOTE: The item number indicates that the item is intended for cylinder heads with the rod diameter of 80 mm. 2) Features It normally requires a tremendous amount of time and effort to extract a bushing because it is press fit with a hydraulic press near the center of the cylinder head. The use of the jig, however, facilitates quick, easy and secure extraction of a bushing from a cylinder head without scratching the inner surface of the cylinder head.

ASM-17-24-002

Issued 08-2008

Copyright © 8012-48 2 List of jigs 1. Jigs for insertion and correction of seal rings

Model

CX75SR

Cyl. name

Part no.

KHV10150

KHV0525

KHV0526

KHV0528

Bore dia.

Ø 85

Ø 95

Ø 100

Ø 110

Boom

Ø 110

Dipper

Ø 95

Bucket

Ø 85

Offset

Ø 95

Blade

Ø 100

O O O O O

2. Jigs for injection and ejection of bushings and wiper rings

Model

CX75SR

Cyl. name

Part no.

KHV10130

KHV10140

KHV0512

Bore dia.

Ø 55

Ø 60

Ø 70

Boom

Ø 70

O

Dipper

Ø 60

Bucket

Ø 55

O

Offset

Ø 55

O

Blade

Ø 60

O

O

3. Jigs for insertion of cylinder heads Part no.

Cyl. name

Rod thread size

KHV10160

Bucket

M42

KHV10170

Offset

M45

KHV10180 KHV10200

ASM-17-24-002

Dipper Blade Boom

Rod dia.

Cushion type

Model

Fastened

CX75SR

Ø 55

M45

Ø 60

M52

Ø 70

Issued 08-2008

Copyright © 8012-49 3 Handling jigs 1) Inserting / correcting seal rings

1) Installing an O-ring Stretch the O-ring by hand and install it in the groove of the piston.

O-ring Piston AQ24002-004

CAUTION: Install O-rings securely without distorting them. Distorted O-rings will cause oil leakages.

Installed properly

O-ring distorted AQ24002-005

2) Attaching the inner guide jig Install the inner guide jig from the top side of the piston.

Inner guide jig O-ring Piston

AQ24002-006

CAUTION: Carefully install the thin edge of the inner guide jig on the top of the piston.

Inner guide jig

Thin edge AQ24002-007

3) Installing a seal ring Apply hydraulic oil to the perimeter of the inner guide and place the seal ring level with the inner guide.

Inner guide jig

Seal ring O-ring

CAUTION: Use caution to keep foreign substances such as dirt, particles and lint from the outside of the inner guide jig.

AQ24002-008

4) Installing an outer guide jig Place a plate on top of the outer guide jig and press down with hand until the seal ring contacts the outer guide jig. CAUTION: The seal ring must not be installed in the inner guide jig, nor could it be at an angle.

Plate Outer guide jig Inner guide jig

Seal ring O-ring Piston

AQ24002-009

ASM-17-24-002

Issued 08-2008

Copyright © 8012-50 5) Press fitting Use a press and push down the seal ring until it fits in the groove of the piston.

Press rod Plate

CAUTION: Use caution while pushing down the seal ring because it may not be properly fit in the groove if it is at an angle in the inner guide jig. Installation of the ring must be carried out swiftly.

Seal ring

Outer guide jig

O-ring

inner guide jig

Piston

AQ24002-010

6) Removing the jigs Remove the jigs in the following order, once confirmed that the seal ring has been completely installed in the groove of the piston. 1. Remove the press rod. 2. Remove the plate. 3. Remove the outer guide jig. 4. Remove the inner guide jig.

Press rod Plate Outer guide jig

inner guide jig

The installation of a seal ring is now complete. The instructions for aligning a seal ring using a correction jig will be given next. Piston

Seal ring (O-ring located inside) #3

7) Preparing a correction jig Place a correction jig under a press. CAUTION: Apply a light coat of oil to the tapered area of the correction jig and place the jig with the tapered side up. Use caution to keep foreign substances such as dirt, particles and lint off the jig.

Press rod

Correction jig

Knurl

AQ24002-012

ASM-17-24-002

Issued 08-2008

Copyright © 8012-51 8) Inserting a piston Install a seal ring to the piston and slowly insert into the correction jig. CAUTION: Insert the piston into the correction jig so that the piston rests level.

Piston Seal ring

Correction jig

AQ24002-013

9) Press fitting Press rod Correction jig Correction range Piston

AQ24002-014

10) Removing the correction jig After the alignment of the seal ring has been completed, remove the jig in the following order. 1. Remove the press rod. 2. Remove the correction jig.

Press rod

Correction jig

The installation and the alignment of the seal ring is now complete. Piston

Seal ring (O-ring located inside) AQ24002-015

Other precautions 1. A specific cylinder bore size requires a specific jig. Refer to the applicable table to choose the correct jig for a specific bore size. 2. The lower part of the inner guide is structurally very thin, requiring extra care and attention for handling and storage. 3. Clean the seal, piston and jigs with compressed air or by other suitable method before installation. Insufficient cleaning may lead to failures such as oil leakage due to foreign substances (dirt, etc.).

ASM-17-24-002

Inner guide jig

Thin edge

AQ24002-016

Issued 08-2008

Copyright © 8012-52 2) Extracting bushings

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

B

CAUTION: The workbench must be clean. Use caution to keep the pipe joint portion from getting scratched by foreign substances such as dirt and particles.

A

AQ24002-017

2) Extracting the snap ring Remove the snap ring (C) that is assembled inside the cylinder head for preventing the bushing from falling out. CAUTION: Secure the cylinder head with a vise, etc. Using the tip of the jig, pry out and remove the snap ring.

C

Screwdriver AQ24002-018

ASM-17-24-002

Issued 08-2008

Copyright © 8012-53 3) Setting the chuck assembly (jig) Gradually insert the chuck assembly in the cylinder head (A) until the blade (D) of the chuck assembly reaches the edge of the bushing.

D

A Chuck assembly jig Working face of head bushing Chuck assembly jig

AQ24002-01

CAUTION: Gradually insert the chuck assembly in cylinder head. Use extra caution to prevent the inner surface of the cylinder head and such from getting damaged by the blade. Also use caution to keep the blade from sticking out the end of bushing.

Chuck assembly jig End face of head bushing

Blade must not stick out AQ24002-020

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

F

E

A

A

CAUTION: With the chuck assembly installed in the cylinder head, firmly grasp both ends of the cylinder head and carefully move to the press workbench.

A

Chuck assembly jig AQ24002-021

ASM-17-24-002

Issued 08-2008

Copyright © 8012-54 5) Attachment the retainer (jig) Place the retainer gently on the notches of the wedge, which is inside the chuck assembly (jig), so the wedge will be covered by the retainer.

Retainer jig

CAUTION: Place the retainer with its larger diameter end up. See the figure to the left. The workbench must be clean. Use caution to keep the chuck assembly bottom from getting scratched by foreign substances such as dirt and particles. Keep it from tipping, also.

Chuck assembly jig Larger diameter end

Retainer jig

Wedge

AQ24002-022

6) Secondary tightening Gradually press down the top of the retainer (jig) so the blade section of the chuck assembly jig bites into the bushing face.

Press retainer jig

CAUTION: Apply 2 to 3 tons of press load. CAUTION: The retainer jig must be used for the pressing procedure.

Cylinder head AQ24002-023

ASM-17-24-002

Issued 08-2008

Copyright © 8012-55 7) Preparing the block (jig) Place the cylinder head on top of the block with the shaft centers aligned.

Block jig AQ24002-024

Refer to the table and choose the block with the proper figuration and size. Category

d1

d2

h

Nominal size

For dia. 75

82

110

80

75

80

87

112

80

80

85

92

124

80

85

90

97

130

80

90

95

102

136

80

95

100

107

140

80

100

105

112

146

80

105

110

117

150

80

110

8) For extracting bushings 1. Move the block (jig) and the cylinder head assembly (with the retainer jig and the chuck assembly jig attached) directly underneath the press. 2. Gradually press down the top of the retainer (jig) until the bushing comes out from the cylinder head (until the bottom of the chuck assembly jig falls on the bench and you actually hear it).

AQ24002-0

Retainer jig Cylinder head

CAUTION: Usually a load of 3 tons or less is needed for the extraction. CAUTION: The stroke of press ram is approximately 32 to 52 mm, depending on the size of the cylinder head. CAUTION: The retainer jig must be used for the pressing procedure. If the shaft centers of the block and the cylinder head assembly do not align with each other, stop the procedure, move the block and align the shaft centers before resuming the operation.

ASM-17-24-002

Block jig

#3

Issued 08-2008

Copyright © 8012-56 9) Removing the chuck assembly (jig) with the bushing attached 1. Pull the cylinder head assembly (with the retainer jig and the chuck assembly jig attached) and the block (jig) toward you from right beneath the press. Remove the retainer from the cylinder head. Grab both ends of the cylinder head with both hands and move from there. 2. Remove the assembly with the bushing attached out of the block and move to the workbench.

Retainer jig

Cylinder head

WARNING: Do not ever attempt to work under the press. Stay safe. Chuck assembly jig (with bushing attached)

Bushing

Block jig

AQ24002-027

10) Removing the bushing 1. Place the chuck assembly (B) with the bushing attached (jig) sideways on the workbench. Insert the hexagon bar wrench (A) in the adjuster head on the chuck assembly tip, plus insert the lever (C) into the round hole at the back of the chuck assembly at the same time. 2. Tip the hexagon bar wrench and the lever back and forth to loosen the adjuster. 3. Reposition the chuck assembly so it stands vertically. Rotate the adjuster with fingers until about 5 mm of the wedge comes out. 4. Verify that the bushing is disconnected from the blade section of the chuck, then gently remove the bushing from the assembly. CAUTION: The workbench must be clean. Use caution to keep the chuck bottom and the periphery from getting scratched by foreign substances such as dirt and particles. Keep it from tipping also.

C A

B

Bushing

AQ24002-028

ASM-17-24-002

Issued 08-2008

Copyright © 8012-57 11) Tightening back the adjuster(A) Once the bushing is removed from the chuck assembly (jig), rotate its adjuster with fingers and tighten until there is no gap between the adjuster and the top surface of the wedge. CAUTION: Do not remove the adjuster and the wedge from the chuck assembly. Keep them in the condition as close to the original as possible.

A

AQ24002-029

Other precautions 1. A specific piston rod diameter requires a specific jig. Refer to the applicable table to choose the correct jig for a specific diameter size. 2. The blade section of the chuck assembly is a vital portion and must be handled and stored with extreme care.

ASM-17-24-002

Issued 08-2008

Copyright © 8012-58 3) Press fitting bushings

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

B

CAUTION: The workbench must be clean. Use caution to keep the cylinder head bottom from getting scratched by foreign substances such as dirt and particles. Keep it from tipping also. Before starting the procedure, remove foreign substances thoroughly with air, etc.

A AQ24002-030

2) Temporarily setting the bushing(B) Temporally place the bushing level inside the cylinder head (A).

B

CAUTION: Verify that inner/outer surfaces of the bushing are free of foreign substances.

A AQ24002-031

3) Setting the chuck assembly (jig) Secure the chuck assembly with fingers and gradually insert into the cylinder head.

B

A AQ24002-032

CAUTION: Verify that the chuck assembly adjuster sits by the wedge with no gap in between.

Chuck assembly jig

Gap between adjuster and wedge Wedge

AQ24002-033

ASM-17-24-002

Issued 08-2008

Copyright © 8012-59 4) Attaching the retainer (jig) Align and gently place the retainer (A) on the notches (B) of the wedge in the chuck assembly.

A

CAUTION: Place the retainer with its larger diameter end up. See the figure to the left.

B

AQ24002-034

5) Preparing for press fitting With the retainer (B) (jig) and the chuck assembly (C) (jig) attached, move the cylinder head (A) right underneath the press.

B

C

A CAUTION: Align the press (ram) axis with the retainer and the chuck assembly axes.

AQ24002-035

Press (ram)

Retainer jig

Chuck assembly jig

Bushing Snap ring grooves

Insert bushing here

Cylinder head AQ24002-036

ASM-17-24-002

Issued 08-2008

Copyright © 8012-60 6) Press fitting the bushing Use a press to push down the bolt head of the adjuster until the bushing reaches the proper position in the cylinder head (A). Keep the press load below 5 tons.

Retaining jig

CAUTION: Check to see if the bushing edge sits at the back of the snap ring grooves. Press fit again if not.

A

7) Removing the retainer (jig) and the chuck assembly (A) (jig) Once the press fitting of the bushing is complete, remove the retainer and the chuck assembly from the cylinder head. Then, attach the seals and press fit the wiper ring.

AQ24002-037

A Retaining jig

CAUTION: Examine to see if the bushing is press fit properly.

AQ24002-038

Other precautions 1. A specific piston rod diameter requires a specific jig. Refer to the applicable table to choose the correct jig for a specific diameter size. 2. The blade section of the chuck assembly is a vital portion and must be handled and stored with extreme care.

ASM-17-24-002

Issued 08-2008

Copyright © 8012-61 4) Press fitting wiper rings

1) Setting the cylinder head Place the cylinder head (A) on a workbench with the mating surface with the tube facing down. CAUTION: The workbench must be clean. Use caution to keep the cylinder head bottom from getting scratched by foreign substances such as dirt and chips from cutting.

A

AQ24002-039

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

A B AQ24002-040

3) Attaching the retainer (B) (jig) Gently place the retainer on top of the cylinder head (A) with the side for wiper ring insertion facing down.

B

CAUTION: Place the retainer gently on top of the cylinder head making sure that it is level with the work bench.

A

ASM-17-24-002

AQ24002-041

Issued 08-2008

Copyright © 8012-62 4) Preparing for press fitting With the retainer (jig) on top, move the cylinder right underneath the press.

A

AQ24002-042

CAUTION: Align the press (ram) axis with the retainer axis.

Press (ram)

Retainer jig Wiper ring Cylinder head AQ24002-043

5) Press fitting the wiper ring Use a press to push down the retainer (B) (jig) head until the wiper ring reaches the proper position in the cylinder head (A). CAUTION: Keep the press load below 1 ton.

B

A

CAUTION: Press fit until the jaws of the retainer reach the end of the cylinder head.

#3

6) Removing the retainer (B) (jig) Once the press fit of the wiper ring (C) is complete, remove the retainer from the cylinder head (A). CAUTION: Examine if the wiper ring is properly press fit.

B C

A AQ24002-045

ASM-17-24-002

Issued 08-2008

Copyright © 8012-63 5) Inserting cylinder head

1) Securing the piston rod Position the piston rod thread (A) in a direction for carrying out the procedure the easiest, then secure.

A

CAUTION: Use extreme care while handling the piston rod to avoid scratches on the outer surface. AQ24002-046

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

B

A

C A

AQ24002-047

3) Inserting the cylinder head Push in the cylinder head assembly till it reaches the proper position: let the assembly slide on the outer surface of the guide (jig) with the side to attach the wiper ring facing the piston rod head. CAUTION: Firmly grab the cylinder assembly by both hands. Use extreme care and do not allow it to drop on your foot. Applying a thin coat of oil to the guide and the outer surface of the piston rod facilitates smooth insertion.

AQ24002-048

ASM-17-24-002

Issued 08-2008

Copyright © 8012-64 4) Removing the guide (jig) Check to confirm that the cylinder head assembly is completely inserted into the piston rod.Then remove the guide from the piston rod. Then, assemble the piston and the other parts on the piston rod. CAUTION: When removing the guide, use extra care to keep the piston rod thread from being damaged.

AQ24002-049

ASM-17-24-002

Issued 08-2008

Copyright ©

8013

Section 8013 DISASSEMBLY AND ASSEMBLY OF THE HAND CONTROL LEVERS

CNH

SM75SR8013-0EN

Copyright © 2008 CNH France S.A. Printed in France July 2008

Copyright © 8013-2

TABLE OF CONTENTS ASSEMBLY/DISASSEMBLY OF OPERATION CONTROL VALVE ...................................................................... 3 MAINTENANCE PROCEDURES ................................................................................................................................. 3 Required tools and tightening torque ................................................................................................................ 3 Maintenance standards ..................................................................................................................................... 3 DISASSEMBLY PROCEDURES ................................................................................................................................. 4 Preparations ...................................................................................................................................................... 4 General work precautions ................................................................................................................................. 4 Disassembly procedure..................................................................................................................................... 4 ASSEMBLY PROCEDURES .................................................................................................................................... 10 Preparations .................................................................................................................................................... 10 General work precautions ............................................................................................................................... 10 Assembly procedures...................................................................................................................................... 10 CAUSES OF TROUBLE AND COUNTERMEASURES .................................................................................................. 15 ATTACHED DIAGRAM 1. REMOTE CONTROL VALVE ASSEMBLY CROSS-SECTION DIAGRAM ....................................... 16 ATTACHED DIAGRAM 2. JOINT DISASSEMBLY JIG .................................................................................................. 17

Lep SM75SR8013-0EN

Issued 03-08

Copyright © 8013-3

ASSEMBLY/DISASSEMBLY OF OPERATION CONTROL VALVE 1 Maintenance Procedures 1 Required tools and tightening torque Tool

Dimensions (mm)

Part number

Hexagon bar wrench

6

125

Wrench

22 32

Special jig (diagram in Attached diagram 2. Joint disassembly jig)

24

Part name

Screw size

Tightening torque (Nm)

M8

20.6±1.5

312 302

Hexagon socket head bolt Adjusting nut Disk

M14 M14

68.6±4.9

301

Joint

M14

47.1±2.9

2 Maintenance standards Maintenance inspection item

Leak amount

Remarks

When handle is in neutral: 1000 cc/min or Conditions more Primary pressure 2.94 MPa During operation: 2000 cc/min or more Oil viscosity 23 mm2/s If either condition occurs, replace the remote control valve as one unit. When wear on the sliding sections exceeds The same approximate conditions as those wear on the non-sliding sections by 10 µm or listed above for leak amount are expected more, replace the remote control valve as one when the condition on the left occurs. unit. If the end section is worn by 1 mm or more, perform replacement. (Ø7)

Spool

Standard

Push rod 1 mm RM10001-005

Operation section backlash

Operation stability

Replace the operation section disk (302) and joint section (301) if there is backlash of 2 mm or more due to wear. If abnormal noise, hunting, or a drop in primary pressure occurs and the problem cannot be resolved with "4. Causes of Trouble and Countermeasures", replace the remote control valve as one unit.

Make adjustments if the backlash is due to looseness in the tightening sections.

NOTE: It is desirable for seal materials such as O-rings to be replaced with each disassembly, but it is acceptable to reuse these after it is confirmed that they are not damaged. Always replace seal washer (121) when a hexagon socket head bolt (125) is loosened.

Lep ASM-17-25-002-EN

Issued 08-08

Copyright © 8013-4

2 Disassembly Procedures 1 Preparations [1] Prepare a sufficiently spacious, solid and stable work platform so that parts will not fall or move during work. [2] Prepare the tools and materials indicated in "1. Maintenance Procedures (1) Required tools and tightening torque". [3] When disassembling the valve, read the disassembly procedures thoroughly before following the sequence below. The numbers in the parentheses after the part names indicate codes in "Attached diagram 1. Remote control valve assembly cross-section diagram Attached diagram 1. Remote control valve assembly cross-section diagram". 2 General work precautions [1] Each part has been manufactured with a high degree of precision, so be careful not to let parts bump each other or fall when handling them. [2] If parts are struck or pulled with excessive force during work because they are tight, this may cause burrs or damage which lead to faulty assembly causing reduction in performance or oil leaking. Perform work carefully and thoroughly. [3] Rust may form on parts due to moisture or debris if the valve is left disassembled or if work is abandoned in the middle of disassembly. If work must be halted, be careful about preventing rust from forming and dust settling on parts. 3 Disassembly procedure [1] Clean the remote control valve with white kerosene. • Place plugs in each port. [2] Use copper plate (or lead plate) to secure the remote control valve in a vise. [3] Remove the bellows (501). • Be careful not to tear the bellows.

RM10001-006


Issued 08-08

Copyright © 8013-5 [4] Use a wrench on the bolt width of the adjusting nut (312) and disk (302) to loosen them, and remove the adjusting nut and disk.

RM10001-007

RM10001-008

RM10001-009


Issued 08-08

Copyright © 8013-6 [5] Use a jig to rotate the joint (301) to the left and loosen it. • The diagram shows the valve with the jig installed. • If the return springs (221) are strong, the plate (151), plugs (211), and push rods (212) will rise at the same time the joint is loosened, so be careful of parts flying off when removing the joint.

RM10001-010

RM10001-011

[6] Remove the plate (151).

RM10001-012

[7] If the return springs (221) are weak, the plugs (211) will remain in the casing (101) due to the sliding resistance of the O-rings (214), so use a flathead screwdriver to remove them. • Use the groove in the outer circumference of the plugs and remove them while making sure they are not damaged by an unbalanced load. • Use caution as plugs may fly off when they are being removed due to the return springs.

RM10001-013


Issued 08-08

Copyright © 8013-7 [8] Remove the push rods (212), plugs (211), pressure reducing valve assemblies and the return springs (221) from the casing (101). Record the relation of parts to the casing hole positions through marking, etc).

RM10001-014

[9] Secure the pilot valve on the vise by facing port plate (111) upward. [10]Loosen and remove the hexagon socket head bolts (125) using a hexagon bar spanner.

[11]Remove also the port plate (111) and O-ring (122) from the casing (101). Draw out the bushing (131) from the casing (101).


Issued 08-08

Copyright © 8013-8 [12]For disassembly of pressure reducing valves, press in the spring seats, move the spring seats (216) to the side while bending the secondary pressure springs (241), and remove the springs from the spools (201) by passing the springs through the larger hole of the spring seats. Next, separate the spools, spring seats, secondary pressure springs, and washers (217). • Be careful not to scratch the surface of the spools. • Do not lower the spring seats by 6 mm or more. • Handle these parts as assemblies until assembly of the remote control valve.

RM10001-015

RM10001-016

[13]Remove push rods (212) from the plugs (211).

RM10001-018


Issued 08-08

Copyright © 8013-9 [14]Remove O-rings (214) and seals (213) from the plugs (211). Use a small flathead screwdriver, etc. to remove seals. • O-rings and seals cannot be reused. Replace them with new parts.

RM10001-019

RM10001-020

[15]Cleaning parts 1) Clean all parts by placing them in a rough cleaning container filled with white kerosene (rough cleaning). 2) Clean all parts by placing them in a finish cleaning container filled with white kerosene, and thoroughly clean them up to the interior while slowly rotating them (finish cleaning). Use a rag to thoroughly remove white kerosene adhered to parts. • Scratching can easily occur if cleaning of parts is begun just after parts are immersed in white kerosene, so let parts sit in white kerosene until debris and grease sufficiently loosen off from the surface of parts and float to the surface. • If the white kerosene is dirty, this will encourage damage to parts and result in reduced performance after reassembly. Thoroughly manage the level of cleanliness of the white kerosene. • Do not dry parts with compressed air, as this will damage parts and cause rust to form due to debris and moisture being dispersed into the atmosphere. [16]Preventing rust on parts Apply an anti-rust agent to each part. • Rust will form on parts if they are left as is after cleaning, and this will cause reduced performance of functions after reassembly.


Issued 08-08


3 Assembly Procedures 1 Preparations [1] As with disassembly, prepare a work platform, tools and materials. 2 General work precautions [1] Observe the same general work precautions as with disassembly. [2] When performing assembly, remove metal fragments and foreign matter from all parts, and check that there are no burrs or nicks on parts. If there are burrs or nicks, use a whetstone to remove them. [3] As a rule, replace all O-rings and backup rings with new parts. [4] When installing O-rings and backup rings, be careful not to damage them. (Apply a thin layer of grease to ensure smooth installation.) [5] When installing parts, using grease is good for preventing parts from falling. [6] Tighten bolts, etc. to the torque values indicated in "Attached diagram 1. Remote control valve assembly crosssection diagram". Use the torque wrench to measure the tightening torque. [7] After assembly is complete, place plugs in all of the ports to prevent entry of debris. 3 Assembly procedures [1] Assemble the bushing (131) and O-ring (122) in the casing (101).

[2] Fit the port plate (111) to the casing (101) using the hexagon socket head bolts (125) and seal washers (121). • Check the assembling positions so that the spring pin (126) are inserted into the casing holes.

•

Replace the seal washers (121).


Issued 08-08

Copyright © 8013-11 [3] Tighten the hexagon socket head bolts (125) by specified torque. • Tighten two screws gradually and alternately.

[4] Insert washers (217), secondary pressure springs (241) and spring seats (216) onto each of the spools (201) in that order.

RM10001-021

Additionally, press in the spring seats and move them to the side while bending the secondary pressure springs to pass the seats over the larger holes and install them on each of the spools. • Do not lower the spring seats by 6 mm or more.

RM10001-022


Issued 08-08

Copyright © 8013-12 [5] Install the return springs (221) in the casing (101). Install the pressure reducing valve assemblies in the casing. • Install them in the positions they were in before disassembly.

RM10001-023

[6] Install O-rings (214) on the plugs (211).

RM10001-024

[7] Install seals (213) on the plugs (211). • Install so that the seal lips are as shown in the diagram below.

1

2

3

4

RM10001-027

*1

RM10001-025

Seal

*2

Plug

*3

Push rod

*4

Hydraulic oil application


Issued 08-08

Copyright © 8013-13 [8] Install push rods (212) into the plugs (211). • Apply hydraulic oil to surface of the push rods.

RM10001-026

[9] Install the plug assemblies into the casing (101). If the return springs (221) are weak, they will be stopped by the sliding resistance of the O-rings (214). • Be careful not to scratch the casing holes by forcing in the spools (201).

RM10001-029

•

If the return springs are strong, use the plate (151) to install all 4 plug assemblies at the same time and temporarily tighten them with the joint (301). Be careful of the plug assemblies and plate flying off.

RM10001-030

[10]Install the plate (151). [11]Use a jig, and tighten the joint (301) to the casing (101) to the specified torque. Tightening torque: 47.1±2.9 Nm

RM10001-031


Issued 08-08

Copyright © 8013-14 [12]Install the disk (302) onto the joint (301). • Screw the disk in until it is equally touching each of the 4 push rods (212). Secondary pressure will cause faulty operation of the machine if the disk is screwed in too much, so pay attention to adjustment of the tightening position.

RM10001-032

[13]Install the adjusting nut (312), use a wrench on the bolt width of the disk (302) to secure it, and tighten the adjusting nut to the specified torque. Tightening torque: 68.6±4.9 Nm • During tightening, do not move the disk position.

RM10001-033

[14]Apply grease to the rotating section of the joint (301) and to the top of the push rods (212).

RM10001-034

[15]Install the bellows (501). • Be careful not to tear the bellows. [16]Inject vapor corrosion inhibitor into each port and then place plugs in the ports.

RM10001-035


Issued 08-08


4 Causes of Trouble and Countermeasures It is not always easy to find where the source of trouble is located. A few problems that may sometimes occur are listed in the table below. Repair of these problems can be difficult, so see the suggested causes and solutions in the table for assistance. The table below shows general symptoms, suggested causes and also solutions. However, the cause of machine problems are often not rooted in just a single part. Problems are often due to the relationship of one part with another. Also keep in mind that solutions other than those listed in the table may sometimes be necessary. The table below does not include all possible causes and countermeasures. Accordingly, further investigation of problems and causes should be done by an experienced and qualified repair person, as necessary. Symptom

Secondary pressure is not rising.

Cause 1 Insufficient primary pressure 2 Secondary pressure spring(s) (241) is (are) broken or worn. 3 The gap between spool(s) (201) and the casing (101) is abnormally large. 4 There is backlash in the handle section.

Secondary pressure is unstable.

1 Sliding parts are sticking. 2 Tank line pressure is variable. 3 Air is getting into lines.

Secondary pressure is high.

1 Tank line pressure is high. 2 Sliding parts are sticking.


Solution 1 Maintain primary pressure. 2 Replace it (them) with new part(s). 3 Replace the remote control valve as one unit. 4 Disassemble and assemble or replace the handle section. 1 Repair the sticking sections. 2 Return directly to the oil tank. 3 Perform operation several times and let out air. 1 Return directly to the oil tank. 2 Repair the sticking sections.

Issued 08-08


5 Attached diagram 1. Remote control valve assembly cross-section diagram

Tightening torque list No.

Screw size

Tightening torque

125

M8

20.6 ± 1.5 Nm

301

M14

47.1 ± 2.9 Nm

312

M14

68.6 ± 4.9 Nm

Grease application to rotating sliding sections. Use caution with installation direction. Grease application to top

Grease application to top

Contain one secondary pressure adjustment shim. Design main value: t = 0.4 x 1

Not to be reused Ports

Code 101 111 121 122 125 126 131

Part name Casing Port plate Seal washer O-ring Hexagon socket head bolt Spring pin Bushing

Ports

Qty 1 1 2 1 2 1 1

Code 214 216-1 216-2 217 221-1 221-2 221-3

151

Plate

1

241-1

201

Spool

4

241-2

Plug Push rod (port 1, 3) Push rod (port 2, 4) Seal

4 2 2 4

301 302 312 501

211 212-1 212-2 213


Part name O-ring Spring seating (port 1, 3) Spring seating (port 2, 4) Washer Return spring (port 1) Return spring (port 3) Return spring (port 2, 4) Secondary pressure spring (port 1, 3) Secondary pressure spring (port 2, 4) Joint Disk Adjusting nut Bellows

Qty 4 2 2 4 1 1 2 2 2 1 1 1 1

Issued 08-08


6 Attached diagram 2. Joint disassembly jig

Bushing

A -A

1 Material: SCM145 N carburized WAF 2 Material: S45C

A

A

Joint installation state

Hole Shaft

Detailed diagram of jig main unit

Detailed diagram of bushing

1 and 2 are inserted by tightening

Material: SCM145 N carburized Quantity: 2 RM10001-037


Issued 08-08


NOTES ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ Lep ASM-17-25-002-EN

Issued 08-08

Copyright ©

Section

DISASSEMBLY AND ASSEMBLY OF THE FOOT CONTROL PEDALS

CNH

Lep SM75SR8014-0EN


8014

8014

Copyright © 8014-2

TABLE OF CONTENTS TRAVEL REMOTE CONTROL VALVE................................................................................................................... 3 OFFSET AND BLADE REMOTE CONTROL VALVE ........................................................................................... 10 At neutral....................................................................................................................................................... 10 During operation (same for port A and port B sides)..................................................................................... 10

Lep SM75SR8014-0EN

Issued 08-2008

Copyright © 8014-3

TRAVEL REMOTE CONTROL VALVE Description

C

C

C

C

T P 4

32

1

Hydraulic Circuit

T

22 34

T

27

30

27

26

21 33

19 26

30

P

31 20

25

1

2

3

4 25

24 5

31

7

20 2 ,4

2, 4 32

18

23

32 23

11

17 35 16 1

9

11

28

16

9

29

1 29

8

8 12

12 13

13 14

14 3, 15

28

10

10

6

3 ,1 5

C-C AQ25002-001

ASM-17-25-002

Issued 08-2008


Part name

Q’ty

No.

Part name

Q’ty

No.

Part name

Q’ty

1

Shim

4

13

Compression spring

4

25

Washer

4

2

Orifice

4

14

Compression spring

4

26

Rivet

2

3

Shim

4

15

Shim

4

27

Pin

4

4

Orifice

4

16

Ring

4

28

Snap ring

4

5

Pin

2

17

Cover

2

29

Steel ball

8

6

Body

1

18

Boot

2

30

Steel ball

2

7

Cam

2

19

Name plate

1

31

Steel ball

4

8

Sleeve

1

20

Holder

4

32

Packing

4

9

Piston

2

21

Plug

1

33

O-ring

1

10

Spool

4

22

Plug

1

34

O-ring

1

11

Pusher

4

23

Hexagon socket head bolt

4

35

O-ring

2

12

Retainer

4

24

Set screw

4

ASM-17-25-002

Issued 08-2008

Copyright © 8014-5 Operational Description This pump has ports P, T and 1 through 4. Because the function and operation of ports 1 through 4 are the same, port 1 will be described here. Pressure reduction function Lever operation range: 0 to 1.8° (Figure 2) • The flow of pressurized oil supplied from port P is cut off from ports 1 and T by spool (10). • Since port 1 communicates with port T by an internal circuit in spool (10) and is connected to the tank through port T, the pressure on port 1 is equal to the tank pressure.

T 10 P

Figure 2

AQ25002-002

Lever operation range: 1.8 to 11° (Figure 3) • When the lever [cam (7)] is operated, the spool is pushed downwards together with pusher (11), piston (9), retainer (12) and spring (14). • When the angle of operation reaches 1.8°, port P and port 1 are connected by means of section I, and the connection between port 1 and port T is closed by means of section II. As a result, pressure is generated at port 1. At this time, the following upward force F acts on spool (10): Pressure P1 at port 1 x spool area a (A) • When P1 increases and F exceeds the force (FS) of spring (14), spool (10) moves upwards, closing section I and opening section II, reducing the pressure on port 1. Repetition of this process causes spool (10) to be balanced in the position shown in Figure 3, and the pressure on port 1 is kept at a constant pressure sufficient to balance the force of spring (14). FS = F = P1 x A

ASM-17-25-002

Issued 08-2008

Copyright © 8014-6 • As the lever is operated further, spring (14) is deflected by pusher (11), piston (9) and retainer (12), increasing the force (FS) of spring (14). At this time, spool (10) generates pressure at port 1 corresponding to the force of spring (14) while balanced in the position shown in Figure 3.

7 11

9 12 T 13 14 ll

P

l 10

Figure 3

AQ25002-003

Lever operation range: 11 to 12.4° (Figure 3) • When the lever operating angle reaches 11°, the head of spool (10) contacts piston (9) (section III), stopping the control of spool (10). • Section I therefore stays open. Section II stays closed and the pressure at port 1 becomes equal to that at port P. • When the lever is released, the force of spring (13) causes all the parts return to neutral position. lll 6 ll

2

l

ASM-17-25-002

Figure 4

AQ25002-004

Issued 08-2008

Copyright © 8014-7 Damper function • When the lever is pressed, the hydraulic oil in damper chamber IV is expelled into port T through restrictor V. At this time, a damping effect is obtained by means of the passage resistance at section V (Figure 5). • When the lever is returned to its original position, the force of spring (13) causes piston (9) to return, and because damper chamber IV becomes a vacuum, the steel ball is lifted, drawing hydraulic oil in through port T, and all the parts return smoothly to neutral position (Figure 6).

lV

30

V

T

Figure 5

T

Figure 6 AQ25002-005

ASM-17-25-002

Issued 08-2008

Copyright © 8014-8 Disassembly and Assembly General precautions • Because all the parts in hydraulic valves are precision components, perform valve disassembly and assembly in a clean and dust-free area. Use clean tools and cleaning solvent. • Clean disassembled parts and apply a corrosion inhibitor. • Number parts when disassembling so that they can be put back in their original locations when assembling. • Clean each part thoroughly, remove foreign substances, and make sure that there are no burrs or dents. If burrs or dents are found, remove them with an oilstone. • Replace seals with new ones each time the valves are disassembled. • When assembling, apply a thin coat of hydraulic oil to sliding surfaces and grease to seals. • During the operation, if a part does not move smoothly, never hit or pry it. Disassembling procedure (Assembly should be done in the reverse order of disassembly). Precautions When disassembling, make note of where each part was assembled, using tags and the like, and be sure to assemble each part into its original location when reassembling. [1] See figure 7. 18 • Remove boots (18). (x 2) • Remove Hexagon socket set screws. (x 2) • Withdraw pins (5). (x 2)

24 7

• Remove cams (7). (x 2) • Remove Hexagon socket head bolts. (x 4)

5

• Remove covers (17). (x 2) • Remove pushers (11). (x 4) • Remove steel balls (31) and holders (20). (4 each)

24

• Remove shims (2 and 4).

17

• Remove U packings. (x 4) Tightening torque: Hexagon socket head bolt: 9.8 ± 1.0 Nm

33 31 20 2,4

Hexagon socket set screw: 9.8 ± 1.0 Nm Disassembly may not be possible if hexagon socket set screws are secured with loctite. In this case, remove the hexagon socket head bolt together with cam (7), pin (5) and cover (10).

11 6

Figure 7

ASM-17-25-002

AQ25002-006

Issued 08-2008

Copyright © 8014-9 [2] See figure 8. • Pull out pistons (9). (x 4) • Remove wires (16) from pistons (9). (x 4) • Remove snap rings. (x 4) • Remove washers (1). (x 4) • Remove steel balls. (x8) (They are very small. Be careful not to lose them.) • Remove sleeves (8). (x 4) • Remove spool assemblies. (x 4) • Remove springs (13). (x 4) • Remove O-rings. (x 2) If wire (16) is deformed during disassembly, replace it with a new one. When attaching snap rings, be careful not to damage the inner surface of body (6).

AQ25002-006

Figure 8

[3] See figure 9. Disassemble spool assemblies. (x 4) • Remove retainer (12). • Remove spring (14). • Remove shims (3 and 15).

AQ25002-006

ASM-17-25-002

Figure 9

Issued 08-2008

Copyright © 8014-10 [4] See figure 10. • Remove flanged plug (21) and remove O-ring(33). (1 each) • Remove flanged plug (22) and remove O-ring (34). (1 each) Tightening torque: No.22 Flanged plug: 24.5 ± 2.0 Nm No.21 Flanged plug: 9.8 ± 1.0 Nm

AQ25002-009

Figure 10

Troubleshooting Symptom External oil leakage. Secondary pressure does not rise smoothly or is outside specified range. Lever does not move smoothly, or does not return to neutral position.

Damping force is weak. Damping force is too strong.

ASM-17-25-002

Cause Scratches on O-ring sealing surface in port sections. Sealing part breakage. Spring (14) is fatigued or broken. Foreign substances lodged in spool (10). Foreign substances lodged in piston (9). Foreign substances lodged in pusher (11). Foreign substances lodged in pin (5) or cam (7). Spring (13) is broken or fatigued. Wire (16) has fallen off. Foreign substances lodged in seat parts in steel ball of sleeve (8). Foreign substances lodged in orifice section (9).

Solution Repair or replace ports. Replace defective sealing parts. Replace springs (16). Disassemble, clean and repair. (Replace as an assembly if repair is impossible). Disassemble, clean and repair. (Replace as an assembly if repair is impossible). Disassemble, clean and repair. Disassemble, clean and repair. Replace springs (15). Disassemble, clean and repair. Disassemble, clean and repair. (Replace as an assembly if repair is impossible). Disassemble, clean and repair.

Issued 08-2008


OFFSET AND BLADE REMOTE CONTROL VALVE 1. Operational Description The numbers in parentheses before the part names correspond to the part numbers in the structural drawing. 1) At neutral P is blocked by spool (11) and ports A and B are connected to T via a small hole inside spool (11). At this time, spool (11) is pressed onto holder (12) by spring (13) and end spool. The holder (12) is pressed onto cover (2) and pusher assembly (23) by spring (6), maintaining the neutral position. 2) During operation (same for port A and port B sides). [1] Rising port pressure As the incline of cam (4) increases, pusher assembly (23) and holder (12) are pressed in, and at the same time, spool (11) moves toward the bottom of cross-section X. Spool (11) blocks T at section (a) (closing A -> T), and as it moves further downward, P -> A opens at section (b), and hydraulic oil enters port A increasing the pressure. This pressure pushes the spring back to block P at section (b), re-opening A -> T and reducing the pressure at port A to balance with the spring force F of spring (13). When the pressure at port A falls below the spring force F of spring (13), spring (13) moves spool (11) downward again, opening P -> A at section (b) and increasing the pressure at port A to balance with spring force F of spring (13). In this way, pressure that balances with the spring force F of spring (13), is generated at port A by the repeated opening and closing of P and T. Spool (11), during this time, stays within the range defined by the opening and closing of P and T. As cam (4) is inclined further, pusher assembly (23) and holder (12) are pressed to an extent corresponding to the angle of incline, and spring (13) bends and the spring force increases. Spool (11), responding to the increase in the force of spring (13), causes repeated opening and closing of P and T as described above, generating pressure at port A that balances with the force of spring (13). In this way, pressure corresponding to the incline angle of the cam is generated linearly at port A. [2] Falling port pressure When cam (4) returns towards the neutral position, spring (6) returns holder spring (12) and pusher assembly (23) upward, towards cross-section X. By this means, the bend of spring (13) decreases and the force is reduced. Spool (11) then opens and closes P and T, generating pressure at port A corresponding to the force of spring (13). 2. Replacing Parts at Servicing [1] Replace sealing parts such as O-rings and backup rings at every disassembly/reassembly. [2] If any of the following symptoms affects a related system, replace the body and spool assembly. 1) When the amount of leakage increases. 2) When the secondary pressure is unstable and is not stabilized by disassembly and adjustment. 3) When hunching or abnormal noises do not go away after disassembly and adjustment. [3] If the steel ball does not rotate in the pusher assembly, replace the pusher assembly. [4] If the cam chatters badly enough to affect operation, replace the parts that are worn 3. Troubleshooting Symptom Secondary pressure does not rise.

Secondary pressure is unstable. Secondary pressure is too high.

ASM-17-25-002

Cause Insufficient primary pressure. Spring fatigue. Abnormal wear of spool and body. Abnormal wear of cam and pusher. Malfunctioning of sliding parts. Air trapped in piping. Fluctuating pressure in circuit T. Malfunctioning of sliding parts. High pressure in circuit T.

Solution Secure primary pressure. Replace or add shims (8) or (9) or (10). Replace the assembly. Replace with new ones. Overhaul. Bleed air. Adjust pressure in circuit T. Overhaul. Adjust pressure in circuit T.

Issued 08-2008

Copyright © 8014-12 4. Disassembling/Assembling Instructions As a general rule, disassembly and reassembly should be done at the factory, but if unavoidable, they should be performed at a service facility with a thorough knowledge of hydraulic devices. Because hydraulic devices are made of precision components put together with small tolerances, disassemble and assemble them in a clean area that is free of dust and handle them carefully, following the instructions below. Never hit a device when it does not move smoothly. [1] Tools required 1) 2) 3) 4)

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

[2] Disassembling Instructions 1) 2) 3) 4) 5)

Remove boots (7). Remove set screws (16). Pull out pins (5). Take out cam (4). Secure the whole assembly in a vise, then loosen hexagon socket head bolts (15) with a 6 mm hexagon bar wrench. Cover (2) may float up due to the force of the spring. 6) Remove cover (2). 7) Pull out pusher assembly (23) from cover (2), then remove O-ring (21) with a scriber. Be careful not to scratch the inside of the cover when removing the O-ring. 8) Remove the spool assembly and O-ring (22) from the body. Record the relative positions of the spool assembly and the hole in the body. 9) To disassemble the spool assembly, secure spool (11) in a vise and fasten end spool with a 2.5 mm hexagon bar wrench. When securing the spool in the vise, use a copper plate to avoid scratching the spool. The pressure of the spool assembly is regulated by shims, and it should not be disassembled if possible. 10) Take out spring (13). [3] Assembling Instructions Fully clean and degrease parts before assembling. The body, in particular, should be cleaned using a nylon brush. Always use new sealing parts, and apply a thin coat of hydraulic oil or grease to them prior to assembly. 1) Assemble O-ring (21) and pusher assembly (23) into cover (2). 2) To assemble the spool assembly, secure spool (11) in a vise, then install flat washer (17), shim (3), (10), spring (13) and spring (12) in that order, and screw on end spool. Tightening torque: 2.94 Nm When securing the spool in the vise, use a copper plate to avoid scratching the spool. Apply loctite 242 to the threaded part. 3) Insert spring (6) into body (1), then install the spool assembly and O-ring (22). The spool assembly is installed in the same hole in the same position as before disassembly. 4) Install shims (8, 9) to each spring holder section (12). Install them in the same position as before disassembly. 5) Secure body (1) in a vise, then fasten cover (2) with hexagon socket head bolts (15). Tightening torque: 23.5 Nm 6) Fasten cam (4) with pin (5). 7) Fasten the pin with hexagon socket set screw (16). Tightening torque: 23.5 Nm Apply loctite 262 to the threaded part. 8) Install boots (7).

ASM-17-25-002

Issued 08-2008

Copyright © 8014-13 5. Structural drawings

A

A

T P B A Hydraulic Circuit

20

T 14 19

P

A

B

23,24,25 4 25

7

16

21

5

18

15

2

12

22

13 8,9 3,10,17

6 11

a

1 b

A-A AQ25002-010

ASM-17-25-002

Issued 08-2008


Part name

Q’ty

No.

Part name

Q’ty

No.

Part name

Q’ty

1

Body

1

10

Shim

2

19

Rivet

2

2

Cover

1

11

Spool

2

20

Pin

2

3

Shim

2

12

Holder

2

21

O-ring

2

4

Cam

1

13

Compression spring

2

22

O-ring

2

5

Pin

1

14

Plate

1

23

Pusher

2

6

Compression spring

2

15

Hexagon socket head bolt

2

24

Pusher

2

7

Boot

1

16

Set screw

1

25

Steel ball

2

8

Shim

2

17

Washer

2

9

Shim

2

18

Washer

2

ASM-17-25-002

Issued 08-2008

Copyright ©

Section

DISASSEMBLY AND REASSEMBLY OF THE THREE SOLENOID VALVES BLOCK

CNH

Lep SM130B8005-0EN


8015

8005

Copyright © 8015-2

TABLE OF CONTENTS SOLENOID VALVE.................................................................................................................................................. 3 ASSEMBLY DRAWINGS ........................................................................................................................................... 3 THEORY OF OPERATION ......................................................................................................................................... 4 MAINTENANCE ...................................................................................................................................................... 4 Assembling and disassembling precautions ..................................................................................................... 4 Assembling and Disassembling a Solenoid Operated Directional Valve .......................................................... 4 Maintenance Standards .................................................................................................................................... 6 Troubleshooting ................................................................................................................................................ 6

Lep SM75SR8015-0EN

Issued 08-2008

Copyright © 8015-3

SOLENOID VALVE 1 Assembly drawings

Normally closed type solenoid: SP, S1

Normally open type solenoid: S2 MQ26001-002

1. 2. 3. 4. 5. 6. 7. 8. 9.

Body (1) Spool (2) Spool (1) Spring (2) Spring (1) Adaptor (3) Snap ring(3) Name plate(1) Spring washer (6)

MSM-17-26-001

10. 11. 12. 13. 14. 15. 16. 17. 18.

Binding band (blue) (1) Binding band (red) (1) Binding band (pink) (1) Solenoid (3) O-ring (3) Hexagon socket head bolt (6) Plug (4) Plug (4) Rivet (2)

Issued 08-2008

Copyright © 8012-4

2 Theory of operation The hydraulic fluid supplied from the port P is fed to the solenoid operated directional valves S1 @ when the valve SP is energized. The hydraulic fluid is then fed to the ports C1 depending on whether or not the valves S1 is energized. Electromagnetic selector valves S1: Oil passes through when energized Electromagnetic selector valves S2: Oil passes through when not energized

NN16001-002

3 Maintenance 1 Assembling and disassembling precautions [1] Disassemble the valve with due attention not to damage the O-ring and other parts, and store the parts in a safe place. [2] If there is any flaw on the O-ring, replace it with a new one. [3] Be careful to assemble the parts in the correct orientation and without forgetting any of the parts. [4] When assembling, reverse the order of disassembling and pay attention not to allow any foreign matters such as dirt to get into the valve. 2 Assembling and Disassembling a Solenoid Operated Directional Valve [1] Remove the mounting bolts from the solenoid (C) and remove the coil part. (Tool: 3 mm Hexagon wrench) [2] Remove the tube, while paying attention not to damage the edges of the flat portion of the core. However, if the core is removed, replace the O-ring (A) with a new one. (Tool: 23 mm spanner) [3] Take out the spools (2) and (3) and the springs (4) and (5). [4] Pry the snap ring (7) off by inserting a flat head screwdriver or the like in the notch, and remove the adapter (6). [5] Assemble the valve by reversing the order of disassembling. When tightening the core, pay attention not to damage the edges of the flat portion of the core. When mounting the adaptor, apply grease or other appropriate lubricant to the O-ring (B) and pay attention not to damage the O-ring.

MSM-17-26-001

Issued 08-2008

Copyright © 8015-5

1.7VQ2.0 Nm

O-ring SO-NA-A022

14.4VQ17.6 Nm

O-ring SO-NB-P18

Item 2 assembly: electronic selector valve SP, S1 Item 3 assembly: electronic selector valve S2 NN16001-003

MSM-17-26-001

Issued 08-2008

Copyright © 8012-6 3 Maintenance Standards

D

d

MQ26001-001

Measure the clearance between the body and the spool. Clearance = Ø D - Ø d Reference value: approx. 0.01mm 4 Troubleshooting Symptom Spool malfunction.

Solenoid malfunction.

Fluid leakage to outside

MSM-17-26-001

Cause Foreign matters galling the spool. Damaged parts or abnormal wear. Terminal disconnection. Damaged coil. Broken lead wire. Loose bolts. Damaged O-ring. Loose hex socket plug.

Solution Remove the foreign matters, dismount the valve, perform flashing, or replace the fluid. Replace the valve. Insert the terminal. Replace the solenoid Tighten the bolt to the specified torque. Replace the O-ring. Fasten the plug.

Issued 08-2008

Copyright ©

Section 8016

8016

DISASSEMBLY AND ASSEMBLY OF THE CUSHION CONTROL VALVE

CNH

Lep SM75SR8016-0EN


Copyright © 8016-2

TABLE OF CONTENTS CUSHION VALVE.................................................................................................................................................... 3 STRUCTURE .......................................................................................................................................................... 3 OPERATIONAL DESCRIPTION .................................................................................................................................. 4 DISASSEMBLY AND ASSEMBLY .............................................................................................................................. 5 General Precautions ......................................................................................................................................... 5 Disassembling procedures ................................................................................................................................ 5 Troubleshooting ................................................................................................................................................ 6

Lep SM75SR8016-0EN

Issued 08-2008

Copyright © 8016-3

CUSHION VALVE 1 Structure

A

B

G 1/4

G 1/4 7 1

A

8

2

6 15

1

13

5

10

B

11

4

12

3

13


1. 2. 3. 4. 5. 6. 7.

Spring Orifice Body Connector Sleeve Plunger Name plate

ASM-17-24-002

8. 10. 11. 12. 13. 15.

Ring Snap ring O-ring O-ring O-ring Plunger assembly

Issued 08-2008

Copyright © 8016-4

2 Operational description A -> B: Flow control (Figure 2) • • • • • •

Hydraulic oil supplied from port A passes through orifice (2) and the hole around plunger (6) and drains out to port B. At this time, the resistance of oil passing through orifice (2) causes the pressure in chamber (1) to become greater than the pressure in chamber (2). The plunger therefore moves to the right. As plunger (6) moves to the right, section (I) is closed, creating a blind circuit, and the pressure in chambers (1) and (2) is equalized. As the pressure in chambers (1) and (2) is equalized, the force of spring (1) returns plunger (6) to the neutral position. Repetition of this process causes plunger (6) to be balanced in a position where the force of spring (1) and the resistance of orifice (2) are equal. (As the flow rate through orifice (2) increases and the resistance increases, section (I) closes). FS = FA - FB (FA = P1 x a > P2 x b = FB)

•

FS:

force of spring (1)

FA:

force to push the plunger to the right

FB:

force to push the plunger to the left

P1:

pressure in chamber (1)

P2:

pressure in chamber (2)

a, b:

outer diameter of plunger (a = b)

Consequently, a flow rate of oil passing through orifice (2) necessary to generate a passing resistance that balances the force of spring (1), is maintained, controlling the flow rate from port A into port B at a constant level. 6

1

5

b

A

2

a

3

(1)

(I)

B

(2)


ASM-17-24-002

Issued 08-2008

Copyright © 8016-5 B -> A: Free flow (Figure 3) • • • •

Hydraulic oil supplied from port B first passes through orifice (2) and drains out to port A. Resistance of oil passing through orifice (2) causes the pressure in chamber (1) to become less than the pressure in chamber (2), moving plunger (6) to the left. As plunger (6) moves to the left, section (II) opens and hydraulic oil passes through the circuit in section (II) and the opening around plunger (6), and the entire flow drains out to port A. When the supply of hydraulic oil is cut, plunger (6) is returned to the neutral position by the force of the 2 springs (1). 3

5

6

b

A

2

a

1

(1)

(II)

B

(2)


3 Disassembly and Assembly 1 General Precautions • Hydraulic valves all consist of precision components. Disassemble and assemble them in a clean area that is free of dust. Use clean tools and solvent. • After disassembly, clean parts and apply a corrosion inhibitor. • During disassembly, number each part to ensure that it is reassembled into its original position. • When reassembling, clean each part well, remove foreign substances, and verify that parts have no burrs or dents. If burrs/dents are found, remove them with an oil stone. • Replace all seals with new ones each time the hydraulic valve is disassembled. • When reassembling, apply hydraulic oil to sliding parts and a thin coating of grease to all seals. • Never attempt to forcibly hit or pry parts when they cannot be moved easily. 2 Disassembling procedures (Reassembly is done in the reverse order of disassembly.) [1] • • •

See figure 4 Remove snap ring (10). Remove sleeve (5). Remove O-rings (13). (x 2) 13

5

10


ASM-17-24-002

Issued 08-2008

Copyright © 8016-6 [2] See figure 5 • Disconnect connector (4). Tightening torque of connector (4): 24.5 ± 2.9 Nm • Remove O-ring (11). 11

4


[3] • • • •

See figure 6 Remove spring (1). Remove the plunger assembly (15). [Orifice (2) and ring (8) cannot be disassembled.] Remove spring (1). Remove O-ring (12). Plunger assembly (15) must be oriented correctly at reassembly. (Install so that ring (8) is visible when viewed from the port A side.) 1

15

12

1

3


3 Troubleshooting Symptom External oil leak

Unstable flow rate at A -> B Oil flow of B -> A blocked from running its entire volume

ASM-17-24-002

Cause Scratches on O-ring seal surfaces at each port. O-ring breakage. Spring (1) is fatigued or breakage. Foreign substance lodged in plunger assembly (15). Foreign substance blocking in orifice (2). Foreign substance lodged in plunger assembly (15).

Solution Repair or replace Replace Replace spring (1) Disassemble to clean and repair or replace. Disassemble and clean. Disassemble to clean and repair or replace.

Issued 08-2008

Copyright ©

Section 8018

8018

DISASSEMBLY AND REASSEMBLY OF THE HYDRAULIC SWIVEL

CNH

Lep SM75SR8018-0EN


Copyright © 8018-2

TABLE OF CONTENTS ROTATING JOINT ................................................................................................................................................... 3 COMPONENT DIAGRAM .......................................................................................................................................... 3 TOOLS AND JIGS ................................................................................................................................................... 4 DISASSEMBLY INSTRUCTIONS ................................................................................................................................ 5 ASSEMBLY INSTRUCTIONS ..................................................................................................................................... 7 ASSEMBLY DRAWINGS ........................................................................................................................................... 9

Lep SM75SR8018-0EN

Issued 08-2008

Copyright © 8018-3

ROTATING JOINT 1 Component diagram

1 2 5 3 4

10 11

6 7,8 1. 2. 3. 4. 5. 6.

Axle V-ring O-ring Paking ring Rotor Cover

ASM-17-17-002

9 7. 8. 9. 10. 11.

AQ17002-001

Hexagon socket head bolt Loctite Snap ring Thrust ring O-ring

Issued 08-2008

Copyright © 8018-4

2 Tools and jigs 1.

Tools 1) Hexagon bar wrench 2) Torque wrench 3) Box wrench 4) Flash light 5) Inspection mirror 6) Brush (vinyl made) AQ17002-002

2.

Jigs

Jig for pushing out axle

M16-M20 Fully threaded bolt L = 350-400 mm M16-M20 Female

Hexagon socket head bolt (7) x 25

Cover (6) fitting size

AQ17002-003

ASM-17-17-002

Issued 08-2008

Copyright © 8018-5

3 Disassembly instructions Prior to disassembly [1] As this is a hydraulic device, follow the cautions below. - Rough handling should be avoided (e.g. forcedly prying and hitting). - Be careful when handling parts; do not drop or hit against other parts. - Do not allow foreign substances such as dirt or moisture to enter into the parts. [1] Always use jigs when disassembling axles and rotors. [1] Use a strongly-built, stable workbench which has enough space. The workspace should be clean and free of dirt and moisture. Remove all dirt and moisture before starting work. [1] Inspect the tools and jigs before starting work. Remove dirt and moisture to make them clean. [1] Use suitable tools and jigs which meet requirements for the job. [1] Follow the procedure below to disassemble rotating joints.. Disassembling procedure 1.

Remove the cover (6) together with the bolt (7).

7

6

AQ17002-004

2.

Remove the O-ring (11).

11

AQ17002-005

3.

Remove the shaft snap ring (9), then remove thrust ring (10).

9 10

AQ17002-006

ASM-17-17-002

Issued 08-2008


Push out the axle (1) from the rotor (5) using a jig.

NOTE: Do not hit the parts with a hammer while carrying out this operation.

5

1

AQ17002-007

5.

Remove the V-ring (2) from the axle (1).

2

1

AQ17002-008

6.

Remove the O-ring (3) and packing rings (4) from the rotor (5).

4 3

5

AQ17002-009

ASM-17-17-002

Issued 08-2008

Copyright © 8018-7

4 Assembly instructions Prior to assembly [1] Clean all the parts. Polish scratches, flashes or burrs using oil stone. Change sealing parts such as O-rings and packing ring with new ones. [1] Prior to the disassembly described in the Section 3-(1), perform the same cautions and measures mentioned in this section. 1. 1) Clean the rotor (5) using cleaning liquid or compressed air. 2) After cleaning, check for scratches, flashes, burrs or dents on the inner sides or grooves of the rotor. NOTE: Do not reuse back-up ring (2) and O-ring (3).

5

AQ17002-010

2.

Check the number of packing rings (4) and the O-rings (3). Apply grease and install them following the steps shown below.

4

1) Set one packing rings (4) in each groove up to the second from the top.

3

2) Set the O-ring (3) in the top groove. NOTE: Do not reuse packing rings (4). Do not reuse O-ring (3).

3

4

AQ17002-011

3.

After installing O-ring and packing ring, check for extrusions or twists using a mirror. Also check for installation errors. After the check is complete, apply grease. After the grease application, check again for extrusion.

5

AQ17002-012

ASM-17-17-002

Issued 08-2008


Install the V-ring (2) to the axle (1), and apply plenty of grease. Ensure that no water or dirt mixes into the grease

2

NOTE: Do not reuse V-ring (2).

1

AQ17002-013

5.

Install the axle (1) to the rotor (5).

NOTE: Be careful not to cause any cuts or damage to the V-ring (2) while setting.

5

1 2

AQ17002-014

6.

Install thrust ring (10) and snap ring (9) onto axle (1).

9 10 1

AQ17002-015

ASM-17-17-002

Issued 08-2008

Copyright © 8018-9

5 Assembly drawings

Apply grease before assembly

Max gap 10.04 Min gap 8.30

Max gap 0.90 Min gap 0.24

M

M M

NOTE: Need treatment free from dust & rust. NOTE: Do not paint M marked surface and port machine surface. 1. 2. 3. 4. 5. 6. 7.

Axle (1) V-ring (1) O-ring (1) Paking ring (9) Rotor (1) Cover (1) Hexagon socket head bolt (4)

ASM-17-17-002

8. 9. 10. 11. 12. 13.

Loctite (-) Snap ring (1) Thrust ring (1) O-ring (1) Drive screw (2) Trade mark plate (1)

Issued 08-2008


NOTES .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... ASM-17-17-002

Issued 08-2008

Copyright ©

Section 8019

8019

DISASSEMBLY AND ASSEMBLY OF THE SWING MOTOR

CNH

Lep SM75SR8019-0EN


Copyright © 8019-2

TABLE OF CONTENTS SWING UNIT............................................................................................................................................................ 3 MAINTENANCE INSTRUCTIONS ................................................................................................................................ 3 Troubleshooting ................................................................................................................................................ 3 Motor function ................................................................................................................................................. 3 Function of valves integrated in motor ............................................................................................................ 5 Parking brake function / hydraulic timer function ............................................................................................ 8 Tools used....................................................................................................................................................... 10 Disassembly .................................................................................................................................................... 13 Removing the anti-reverse valve................................................................................................................... 13 Separating the motor and the reduction gears.............................................................................................. 14 Disassembling the motor section .................................................................................................................. 14 Disassembling the reduction gears ............................................................................................................... 19 Assembling instructions .................................................................................................................................. 23 Assembling the motor section ....................................................................................................................... 23 Assembling the reduction gears.................................................................................................................... 29 Reassembling the entire motor assembly ..................................................................................................... 34 Installing the anti-reverse valve..................................................................................................................... 34 Checking Quality after Assembly .................................................................................................................... 35 Check for air leaks in the motor section ........................................................................................................ 35 Inspection before and after operation ........................................................................................................... 35 Maintenance Standards .................................................................................................................................. 36 Motor section................................................................................................................................................. 36 Reduction gear section ................................................................................................................................. 37 Valve section................................................................................................................................................. 37 Other ............................................................................................................................................................. 37 Exploded views ............................................................................................................................................... 38 Stracture drawing ............................................................................................................................................ 40 ANTI-REVERSE VALVE.......................................................................................................................................... 42 Troubleshooting .............................................................................................................................................. 42 Tools used....................................................................................................................................................... 43 Disassembling instructions.............................................................................................................................. 43 Precautions prior to disassembly .................................................................................................................. 43 Disassembly.................................................................................................................................................. 43 Assembling instructions .................................................................................................................................. 44 Precautions prior to reassembly.................................................................................................................... 44 Assembly....................................................................................................................................................... 44 Anti-reverse valve: Exploded view .................................................................................................................. 46

Lep SM75SR8019-0EN

Issued 08-2008

Copyright © 8019-3

SWING UNIT 1 Maintenance instructions 1 Troubleshooting If any problems occur in the swing motor, as a general rule, replace the entire assembly. Problems, causes and remedies are described below for reference and understanding. 1 Motor function Problem

1. Motor does not rotate.

2. Motor rpms are insufficient.

3 .Large variation in motor rotation.

ASM-17-22-002

Cause

Remedy

1. Malfunction of something other than the piston motor, valves (integrated in motor) or reduction gears.

Check to see if the oil pressure at the entry side of the motor is correct. Then inspect/repair each device.

2. Escaping hydraulic oil due to abnormal wear on motor sliding sections.

Replace parts with abnormal wear. Clean all parts completely and remove surface burrs and scratches. Reassemble, taking care to keep foreign substances out of parts.

3. Malfunction due to breakage of major motor components. In this case, the motor itself makes abnormal sounds.

After disassembly, replace damaged parts. Clean all parts completely and reassemble, taking care to keep foreign substances from getting into parts.

4. Malfunction due to breakage of major reduction gear components. In this case, the reduction gears make abnormal sounds.

After disassembly, replace damaged parts. Clean all parts completely and reassemble, taking care to keep foreign substances out of parts.

5. Too much load on the motor activates the relief valve.

Check load and run motor with a load that matches relief set pressure.

1. Insufficient motor revolutions due to lack of oil supply to motor, caused by problems related to hydraulic pump, pressure control valves, etc.

Check to see if the amount of oil supplied to the entry side of the motor is correct. Then inspect/ repair each device.

2. Motor rpms are reduced due to decreased motor volumetric efficiency.

Disassemble and check sliding sections for abnormal wear, then repair or replace.

1. Wear on sliding sections causes a large amount of highly-pressurized hydraulic oil to leak and flow out from the drain port, reducing rpms significantly and causing rotation to vary. Variation in rotation is also caused by wear on shaft bearings.

After disassembly, replace parts that show abnormal wear. Clean all parts completely and reassemble. Take measures to prevent foreign substances from getting into parts.

Issued 08-2008

Copyright © 8019-4 Problem

4. Oil leak.

5. Abnormal noises, fluctuation in rotation/ pressure due to cavitation.

ASM-17-22-002

Cause

Remedy

1. Damaged oil seal or O-ring causes oil to leak.

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

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

Repair motor according to instructions in 1.2 and 3.1 and then replace oil seal with new one. Special care should be taken when inserting oil seals so that lips will not be damaged.

3. Drain pipe is blocked by foreign substances, or long narrow piping causes increased back pressure, leading to oil seal breakage and oil leakage. - Oil seal - Withstand pressure: 3 kgf/cm2 (instantaneous maximum) - Normal use:1 kgf/cm2 or less

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

1. Increased drain volume due to low motor efficiency.

Take measures described in 2.2 and 3.1.

2. Makeup valve malfunction.

Take measures described 1.4 under Valve functions.

3. Insufficient pressure on makeup valve due to lack of supply flow.

Check makeup supply pressure and oil level, then reset to defaults.

Issued 08-2008

Copyright © 8019-5 2 Function of valves integrated in motor Problem

Cause

Remedy

1. Malfunction of something other than the piston motor, valve (integrated in motor), or reduction gears.

Check to see if the oil pressure at the entry side of the motor is correct. Then inspect/repair each device.

2. Increased internal leakage due to Oring seal breakage in relief valve.

Replace O-rings and backup rings with new ones.

3. Increased leakage due to bad seal in valve and piston section.

Repair, or replace piston and rear cover with new ones.

4. Faulty seat or malfunction in makeup valve. 1) Foreign substances present.

1. Motor does not rotate or rotational speed is low.

2) Roughness or breakage on sliding faces of check valve. 3) Damaged spring.

5. Faulty seat in relief valve. 1) Foreign substances present.

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

ASM-17-22-002

1) Remove foreign substances completely and repair where damaged. Clean and reassemble. Replace if scratches are deep and leak is large. 2) Repair sliding faces or replace part with new one. 3) Replace spring. Then remove foreign substances completely and repair valve where damaged. Clean and reassemble. Replace if scratches are deep and leak is large. 1) Remove foreign substances completely and repair where damaged. Clean and reassemble. Replace if scratches are deep and leak is large. 2) Replace relief valve assembly.

1) Replace relief valve assembly. 2) Clean with mineral oil, then reassemble.

1) Take measures described in 1.2 and 1.3 to solve problem. 2) Replace relief valve assembly.

Issued 08-2008


Cause 1. Faulty seat or malfunction in makeup valve. 1) Foreign substances present.

2) Roughness or breakage on sliding faces of check valve. 3) Damaged spring.

2. Motor does not stop, or does not stop immediately.

2. Faulty seat in relief valve. 1) Foreign substances present.

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

2) Damaged spring. 3. Abnormal noises.

ASM-17-22-002

Remedy

1) Remove foreign substances completely and repair where damaged. Clean and reassemble. Replace if scratches are deep and leak is large. 2) Repair sliding faces or replace part with new one. 3) Replace spring. Then remove foreign substances completely and repair valve where damaged. Clean and reassemble. Replace if scratches are deep and leak is large. 1) Remove foreign substances completely and repair where damaged. Clean and reassemble. Replace if scratches are deep and leak is large. 2) Replace relief valve assembly.

1) Replace relief valve assembly. 2) Clean with mineral oil, then reassemble.

1) Take measures described in 1.2 and 1.3 to solve problem. 2) Replace relief valve assembly.

1) Remove foreign substances completely and repair where damaged. Clean and reassemble. Replace if scratches are deep and leak is large. 2) Replace spring. Then remove foreign substances completely and repair valve where damaged. Clean and reassemble. Replace if scratches are deep and leak is large.

2. Insufficient pressure/oil flow to makeup valve.

Check makeup pressure and oil flow and reset to specified values.

3. Relief valve set pressure changes, causing resonance in other relief valves.

Readjust relief valve set pressure.

Issued 08-2008


Cause 1. Shockless feature does not operate. 1) Foreign substances present.

4. Greater than usual shock at swing stops.

ASM-17-22-002

2) Hydraulic oil is not supplied to piston chamber. 3) Increased leakage due to abnormal wear on piston sliding part.

Remedy 1) Remove foreign substances completely. Clean damaged parts and repair, then reassemble. Replace if scratches are deep and leak is large. 2) Clean relief valve assembly and remove foreign substances blocking orifice section. 3) Repair or replace sliding part.

2. Relief valve set pressure is increased.

Readjust relief valve set pressure.

3. Relief valve does not operate. Foreign substances present in sliding section.

Remove foreign substances completely. Clean damaged parts and repair, then reassemble. Replace if scratches are deep and leak is large.

Issued 08-2008

Copyright © 8019-8 3 Parking brake function / hydraulic timer function (References to models with parking brake/hydraulic timer specifications only are indicated in parentheses). Problem

1. Motor does not rotate. Parking brake does not release.

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

Adjust PB (PG) and SH pressure to specified values.

2. Valve does not operate because motor drain pressure is high.

Measure motor drain pressure, inspect drain circuit for blockage and repair. If motor drain volume is abnormally large, inspect and repair motor.

3. Timer valve does not switch over (models with hydraulic timer specifications only). 1) Malfunction due to wear or damage to sliding section of valve body. 2) Malfunction due to foreign substances engaged in sliding section of valve body. 3) Damaged spring. 4. Brake piston does not operate. 1) Hydraulic oil escapes due to abnormal wear or breakage of O-ring in brake piston. 2) Piston malfunction due to wear or damage to brake piston or sliding section. 3) Malfunction due to foreign substances lodged in piston sliding section.

ASM-17-22-002

Remedy

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

2) Replace if damage to sliding section is serious.

3) Clean sliding section and remove foreign substances.

Issued 08-2008


Cause

Remedy

1. Worn abrasive material on disks.

Replace disks with new ones.

2. Fatigue or breakage of springs in piston section.

Replace springs with new ones.

3. Faulty sliding section or warping in brake piston, or deformation of abrasive face of disk.

Repair sliding face, or replace parts if damage is serious. Surfaces of abrasive material cannot be repaired.

4. Timer valve does not switch over and pressure cannot be released from cylinder chamber (models with hydraulic timer specifications only). 2. Poor braking power. No braking power.

1) Valve spring fatigue.

1) Replace spring.

2) (Models with hydraulic timer specifications only:) Signal pressure SH is supplied or signal system back pressure is high. 3) For other problems, see 1.3. 1) - 3).

2) Check pressure in SH signal system. If back pressure is high, take measures to reduce to specified value.

5. Pressure cannot be released from cylinder chamber because of blockages in orifice and filter.

3) For other problems, see 1.3. 1) - 3).

Clean filter and orifice, or replace with new ones.

1. Brake piston rubs on disk because release pressure PB (PG) is low. 2. Decreased pressure in cylinder chamber due to abnormal wear or breakage of O-ring in brake piston.

3. Parking brake does not release completely, generating noises, vibratory shocks, abnormalities and heat.

3. For malfunctioning timer valve, see 2.4. 1) - 3). 4. Faulty hydraulic timer section. (Models with hydraulic timer specifications only:) Parking brake operates as a dynamic brake because timer is set too early. 1) Orifice is not positioned correctly. 2) Faulty valve seat. 3) Foreign substances engaged in the above valve seat. 4) Spring fatigue or breakage.

ASM-17-22-002

1) Disassemble to inspect valve, then assemble orifice correctly. 2) If abnormal damage is found on seat surface, repair or replace with new one. 3) Clean new parts and remove foreign substances. 4) Replace spring with new one.

Issued 08-2008

Copyright © 8019-10 2 Tools used No

Name

1

Plastic hammer Hexagon wrench

2

Screwdriver (flathead)

3

Snap ring pliers (internal)

4

Snap ring pliers (external)

5

Hand press

6

Vise


Hexagonal wrenches

Width across flats 2.5 mm 3 mm 5 mm 6 mm 8 mm 12 mm

Torque wrench

Troque settings 2.45 Nm 15.7 Nm 24.5 Nm 32.4 Nm 39.2 Nm 70 Nm 157 Nm 177 Nm 373 Nm

9

Bits for torque wrench

Width across flats 2.5 mm 3 mm 5 mm 6 mm 8 mm 12 mm

10

Socket

Width across flats: 27

11

Tweezers

12

Needle nose pliers

7

8

ASM-17-22-002

Issued 08-2008

Copyright © 8019-11 Tool name............................................................................................................................... Configurations for reference 1.

Ball bearing press fitting jig (2-3).

AQ22002-001

2.

Ball bearing press fitting jig (2-28).

AQ22002-002

3.

Oil seal press fitting jig (1-7).

AQ22002-003

ASM-17-22-002

Issued 08-2008

Copyright © 8019-12 Tool name............................................................................................................................... Configurations for reference 4.

Collar press fitting jigs (1-10).

AQ22002-004

ASM-17-22-002

Issued 08-2008

Copyright © 8019-13 3 Disassembly

!

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

[1] Disassembly Disassemble the valve following the procedure below:

!

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

1 Removing the anti-reverse valve *1, anti-reverse valve specifications only Remove socket head bolts (2-39), and remove antireverse valve (2-34) and O-ring (2-38). See the Antireverse Valve Instruction.

2-38 2-36

2-34

2-39 AQ22002-006

ASM-17-22-002

Issued 08-2008

Copyright © 8019-14 2 Separating the motor and the reduction gears [1] Secure the entire motor assembly firmly in a vise or the like, then remove socket head bolts (3).

3

AQ22002-007

3 Disassembling the motor section 1 Secure the motor assembly firmly in a vise or the like. Remove socket head bolts (2-33) and separate off cover assembly (2-27).

2-33

2-33

NOTE: Handle carefully so that valve plate (2-30) does not fall when cover assembly (2-27) is separated off.

2-33 2-30

2-33 2-27

AQ22002-008

ASM-17-22-002

Issued 08-2008

Copyright © 8019-15 2 Remove valve plate (2-30) and pins (2-32, 2-29). 2-30

!

2-29

2-32

WARNING: Valve plate (2-30) may remain on the motor side. 3 Remove bearing (2-28).

!

WARNING: Do not disassemble unless absolutely necessary. Bearings, once removed, cannot be reused.

2-28

AQ22002-010

4 Disassemble the check valve. 1) Loosen and remove plug (2-27-3).

2-27-3

AQ22002-011

2) Remove check valve (2-27-2) and spring (2-27-5).

2-27-5

2-27-2

AQ22002-012

5 Remove the relief valve. 1) Loosen plug (2-27-6-6) and remove relief valve assembly (2-27-6).

!

WARNING: Do not touch set screws and nuts (2-276-13 and 14). Doing so will change the pressure settings. Relief valve assembly (2-27-6) is a functional component and should not be disassembled.

2-27-6-13

2-27-6-3

2-27-6-14

2-27-6-6 AQ22002-013

!

WARNING: When removing the relief valve assembly, poppet sheet (2-27-6-3) may remain on the cover side.

ASM-17-22-002

Issued 08-2008

Copyright © 8019-16 6 Remove pin (2-31) and O-ring (2-24).

!

WARNING: Pin (2-31) may remain on the cover assembly side.

2-31

2-24

AQ22002-014

7 (*2, parking brake specifications only) [1] Remove springs (2-22, 2-23), then remove parking pilot brake piston (2-19) using the pilot port on case (2-1).

!

2-23

2-22

2-19

WARNING: Use caution in this operation: air pressure may cause the piston to fly out. Also, set air pressure low at the beginning of the operation and adjust it while watching the piston.

Pilot port

AQ22002-015

8 Cover collar (2-17) (*2, parking brake specifications only) 2-17

!

2-15

WARNING: Removing one disk (2-15) first makes this procedure easier.

NOTE: Be careful not to deform the friction plate while removing the collar.

AQ22002-016

9 Remove the cylinder block and related parts: Cylinder block (2-6), etc. - Pin (2-11) - Retainer holder (2-13) - Retainer plate (2-12) - Piston assembly (2-14) (*2, parking brake specifications only) Remove disk (2-15) and friction plate (2-16).

2-11

2-6

2-14 2-16

2-15

2-12

2-13 AQ22002-017

ASM-17-22-002

Issued 08-2008

Copyright © 8019-17 10 Remove retainer plate (2-12) and piston assembly (2-14).

2-12

2-14

AQ22002-018

11 Remove pin (2-11) and retainer holder (2-13). 2-13

2-11

AQ22002-019

12 Remove snap ring (2-10) while pressing down on washer (2-9).

!

2-10

2-9

WARNING: Do not disassemble unless absolutely necessary. As a general rule, rotary parts (B1) should be replaced as a cylinder block assembly.

AQ22002-020

13 Remove collar (2-7), spring (2-8) and washer (29).

!

2-9

2-7

2-8

WARNING: Do not disassemble unless absolutely necessary. As a general rule, rotary parts (B1) should be replaced as a cylinder block assembly.

AQ22002-021

ASM-17-22-002

Issued 08-2008

Copyright © 8019-18 14 Remove thrust plate (2-5).

2-5

AQ22002-022

15 Remove shaft (2-4) by tapping the end of the shaft lightly with a plastic hammer.

2-4

AQ22002-023

16 Disassemble shaft (2-4) and ball bearing (2-3). 2-3

!

2-4

WARNING: Do not disassemble unless absolutely necessary. Bearings, once removed, cannot be reused.

AQ22002-024

ASM-17-22-002

Issued 08-2008

Copyright © 8019-19 4 Disassembling the reduction gears 1) Remove: - O-ring (1-37) - Thrust plate (1-24) - Drive gear (1-25) - Planetary gear (1-23) - Needle bearing (1-22) - Inner race (1-21) - Thrust washer (1-20) - Holder (1-19)

1-23

1-20

1-21

1-25

1-22

1-24

1-37

1-19

AQ22002-025

2) Remove planetary gear (1-18). 1-18

AQ22002-026

ASM-17-22-002

Issued 08-2008

Copyright © 8019-20 3) Remove holder (1-11) etc.

1-11

AQ22002-027

4) Loosen screw (1-17) and remove thrust plate (1-16).

!

WARNING: This screw may be hard to remove because Loctite is used in the assembly. In this case, heating the screw section with a dryer facilitates its removal.

1-16

1-17

1-11 AQ22002-028

5) Remove: - Planetary gear (1-15) - Needle bearing (1-14) - Inner race (1-13) - Thrust washer (1-12)

1-13

1-14 1-15

1-12 AQ22002-029

ASM-17-22-002

Issued 08-2008


!

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

1-1

1-7

1-8

1-9

1-10

1-5

1-6 1-4

6) Remove collar (1-10) and plate (1-9). 1-2

1-3 AQ22002-030

7) Remove pinion shaft (1-2). NOTE: When removing the shaft, be careful not to let it fall. If it is hard to remove, tap it lightly with a plastic hammer.

1-2

AQ22002-031

8) Remove the inner race of tapered roller bearing (1-8). 1-8

AQ22002-032

ASM-17-22-002

Issued 08-2008

Copyright © 8019-22 9) Break oil seal (1-7) and remove. NOTE: Oil seals that have been removed cannot be reused. Be careful not to damage the outer races of tapered roller bearings (1-6, 1-8) during removal.

1-7

AQ22002-033

10) Remove plug (1-35).

1-35

AQ22002-034

ASM-17-22-002

Issued 08-2008

Copyright © 8019-23 4 Assembling instructions

!

WARNING: Precautions prior to assembly 1 Clean each part with clean mineral oil and dry with air. 2 Handle cleaned parts carefully to keep them from getting dirty, dented or scratched. 3 Replace all seals. 4 Fasten all tightened parts to specified torques. 5 Apply lithium grease in advance to oil seals and O-rings. 6 There are many small parts. Be careful not to lose them (especially not to let them fall into holes).

[1] Assembly Assemble the motor following the procedure below: 1 Assembling the motor section 1 Install collar (2-7), spring (2-8) and washer (2-9) into cylinder block (2-6).

2-9

2-7

2-8

2-6

NOTE: Be careful to orient collars (2-7) correctly. Tapered face

Cylinder block AQ22002-036

2 Install snap ring (2-10) while pressing on washer (29).

AQ22002-035

2-9

2-10

NOTE: Make sure that the snap ring is firmly secured.

AQ22002-037

3 Apply grease to pins (2-11) and install them in cylinder block (2-6). 4 Install retainer holder (2-13).

2-13

2-11 2-6

AQ22002-038

ASM-17-22-002

Issued 08-2008

Copyright © 8019-24 5 Place retainer plate (2-12) on piston assembly (2-14) and install on cylinder block (2-6). Coat sliding sections thoroughly with hydraulic oil before installing.

2-12

2-14

2-6

NOTE: Be careful to orient the retainer plate correctly.

AQ22002-039

6 Press fit ball bearing (2-3) onto shaft (2-4). (Reference jig No.21)

2-4 2-3

AQ22002-040

7 Press fit shaft (2-4) and ball bearing (2-2) into case (2-1).

2-4

AQ22002-041

ASM-17-22-002

Issued 08-2008

Copyright © 8019-25 8 Apply grease to back surface of thrust plate (2-5) and install.

2-5

NOTE: Thrust place must be oriented correctly.

Please tapered side on motor case side AQ22002-043

AQ22002-042

9 Apply grease to front surface of thrust plate (2-5) and install cylinder block ASSY. Cylinder block ASSY - Cylinder block (2-6) - Pin (2-11) - Retainer holder (2-13) - Retainer plate (2-12) - Piston ASSY (2-14)

2-6

AQ22002-044

10 (*2, parking brake specifications only) Install disk (2-15) and friction plate (2-16). NOTE: Disk and friction plate must be oriented correctly.

!

2-15

2-16

WARNING: Assemble by aligning disks in the locations on the spline without teeth.

AQ22002-045

11 (*2, parking brake specifications only) Apply grease to O-ring (2-18) and install on collar (217).

!

2-17

2-18

WARNING: Always press fit using a press or the like. If hit with a plastic hammer or the like, the cylinder block will bounce and cause the disk plate and friction plate to fall off.

AQ22002-046

ASM-17-22-002

Issued 08-2008

Copyright © 8019-26 12 (*2, parking brake specifications only) Apply grease to O-rings (2-20, 2-21) and install on brake piston (2-19).

2-19

13 (*2, parking brake specifications only) Install brake piston (2-19) into case (2-1).

!

WARNING: Press fit brake piston positioned as shown in the figure to the left. (Otherwise, the pin will not connect with the cover). Always press fit using a press, etc. If hit with a plastic hammer or the like, the cylinder block will bounce and cause the disk plate and friction plate to fall off.

2-20

2-21 AQ22002-047

Install so that pin hole (DIA 8.5) is positioned at this location AQ22002-048

14 Apply grease to 12 large springs (2-22), 8 small springs, (2-23) and O-ring (2-24), then install.

2-23

2-22

2-19

2-24

AQ22002-049

!

Pin hole

WARNING: Install small springs (2-23) in the locations shown below.

Pin hole AQ22002-050

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Issued 08-2008

Copyright © 8019-27 15 Install greased O-rings (2-27-6-7, 15, 17) and backup rings (2-27-6-16, 18) on relief valve (2-27-6), and then install it on cover (2-27-1).

2-27-6-7

2-27-6-18

2-27-6-16 2-27-6-3

Tightening torque: 37±20 Nm (Width across flats: 27) NOTE: Poppet sheet (2-27-6-3) may remain inside the cover.

2-27-6-17

2-27-6-15 AQ22002-051

16 Attach check valve (2-27-2) and spring (2-27-5) onto cover (2-27-1). Install plug on cover (2-27). Tightening torque: 157±10 Nm (Width across flats: 12)

2-27-5

2-27-2

AQ22002-052

17 Apply grease to O-ring (2-27-4) and install onto plug (2-27-3). Install plug on cover (2-27).

2-27-4

Tightening torque: 157±10 Nm (Width across flats: 12) 2-27-3

AQ22002-053

18 Press fit ball bearing (2-28). (Reference jig No. 22) Install pins (2-31, 32) onto cover (2-27-1) and then screw in orifice (2-27-7).

2-27-7 2-31

2-28

2-32

NOTE: After orifice (2-27-7) is screwed in, crimp it around the perimeter.

2-27-1

ASM-17-22-002

AQ22002-054

Issued 08-2008

Copyright © 8019-28 19 Install pin (2-29) and attach valve plate (2-30). Apply grease to back face to keep it from falling off. 2-31

2-30

2-29

AQ22002-055

NOTE: After installing pin (2-29), crimp the following locations using a punch:

6 (range crimped with punch

2-29

Crimp one location with punch (center side of motor) Pin (2-29) crimping location

AQ22002-056

20 Install cover assembly (2-27) on case (2-1), keeping an eye on the locations of pins (2-31, 2-32).

2-31

2-30

2-27

2-32

NOTE: Be careful not to drop the pin or the valve plate. NOTE: Refer to notes in section 1-13: Installing Brake Piston for location of pin (2-32).

AQ22002-057

21 Finger tighten socket head bolt (2-33), then tighten to specified torque.

2-33

2-33

2-33

2-33

Tightening torque: 177±10 Nm (Width across flats: 12) NOTE: Parts related to the pinion shaft should be replaced as a housing assembly (B6). Description below is for reference purposes only.

AQ22002-058

ASM-17-22-002

Issued 08-2008


1 Press fit oil seal (1-7). Press fitting dimension: 4.25 (shown in the figure to the left). Prior to press fitting, apply grease to the mounting site of the oil seal in the housing and the outer surface of the oil seal. (Reference jig No. 23).

Dimension of oil seal after press fitting: 4.25

2 Assembling the reduction gears (reference) 1-7

AQ22002-059

2 Apply grease to the inner race of tapered roller bearing (1-6), which is installed in pinion shaft (1-2). Amount of grease packed: 80 to 90 cm2 (approx. 66 to 75 g).

1-2

1-6

AQ22002-060

ASM-17-22-002

Issued 08-2008

Copyright © 8019-30 3 Install pinion shaft (1-2), etc. Install inner race of tapered roller bearing (1-8). Apply grease to lip of oil seal (1-7) before installing pinion shaft (1-2), etc. Before installing pinion shaft, verify that plug (1-35) is not attached. Installing the pinion shaft with the plug attached increases the air pressure inside, and this may cause damage to oil seal (1-7).

1-7

1-8

1-2

AQ22002-061

4 Install collar (1-10) while applying load 1177ON to the inner race of tapered roller bearing (1-8). (Reference jig No. 24) Apply grease to O-ring (1-36) and install on plug (1-35). Install plug in housing (1-1).

1-1

1-8

1-9

1-10

Tightening torque: 15.7±0.8 Nm (Width across flats: 5) 1-35

1-36

AQ22002-062

ASM-17-22-002

Issued 08-2008

Copyright © 8019-31 5 Install thrust washer (1-12), inner race (1-13), needle bearing (1-14) and planetary gear (1-15) onto holder (1-11).

1-13

1-14

1-11

1-15

1-12 AQ22002-063

6 Install thrust plate (1-16) and screw (1-17) onto holder (1-11). Apply Loctite 242 to screw before fastening. 1-16

Tightening torque: 24.5±4.9 Nm (Width across flats)

1-17

1-11 AQ22002-064

7 Install holder (1-11), etc.

1-11

AQ22002-065

8 Install snap ring (1-26) on sun gear (1-18). 1-26

1-18

Install snap ring with side marked with R facing this way. AQ22002-066

ASM-17-22-002

Issued 08-2008

Copyright © 8019-32 9 Install sun gear (1-18). 1-18

AQ22002-067

10 Install holder (1-19).

1-19

AQ22002-068

ASM-17-22-002

Issued 08-2008

Copyright © 8019-33 11 Install - Thrust washer (1-20) - Inner race (1-21) - Needle bearing (1-22) - lanetary gear (1-23) - Thrust plate (1-24) - Drive gear (1-25) - O-ring (1-37)

1-23

1-20

1-21

1-25

1-22

1-24

1-37

AQ22002-069

!

WARNING: When replacing any component part of the reduction gear, measure the dimensions shown below and select one thrust plate (1-24) from thrust plate kit (B5) according to the selection table. Thrust Plate Selection Table (1-24)

(Reference)

Dimension E (Measured dimension)

5.3 to <5.8

5.8 to <6.5

6.5 to 7.0

B0841-23031 2.8 ± 0.14

B0841-23030 2.3 ± 0.12

B0841-23029 1.8 ± 0.10

7.96 to 8.74

7.98 to 8.72

8.2 to 8.9

(Between inner rance and housing)

Part No. (plate thickness)

For thrust plate (1-24) Dimension F (Measured dimension)

AQ22002-070

ASM-17-22-002

Issued 08-2008

Copyright © 8019-34 3 Reassembling the entire motor assembly 1 Place the reduction gear assembly on the motor assembly, verify its orientation, finger tighten socket head bolt (3), and then tighten to the specified torque.

3

Tightening torque: 177±10 Nm (Width across flats: 12).

AQ22002-071

4 Installing the anti-reverse valve (*anti-reverse valve specifications only)

2-38

2-27-1

1 Install O-ring (2-38) on cover (2-27-1). 2 Place valve assembly (2-34) on cover (2-27-1) and fasten socket head bolt (2-39). Tightening torque: 32.4±2.0 Nm (Width across flats: 6) NOTE: (Refer to the Anti-reverse Valve Instruction (40 page) for instructions for disassembling and reassembling antireverse valves.) Remove deep groove ball bearing (149) from shaft (102) by pressing on the shaft end with press.

2-34

2-39 AQ22002-072

ASM-17-22-002

Issued 08-2008

Copyright © 8019-35 5 Checking Quality after Assembly

!

WARNING: Check the following before and after operation.

1 Check for air leaks in the motor section Fill the motor case with compressed air (0.3 MPa) through the drain port, and verify that no bubbles are given off in water for a period of two minutes. 2 Inspection before and after operation 1 Prior to starting the motor, fill the piston motor case with clean hydraulic oil. 2 Bleed air at each piping section. 3 Operate at low speed at first, and then increase the engine rotations and apply load after confirming that there are no abnormal sounds or vibrations. 4 Check the following after operation: 1) Is there any oil leakage? 2) Are the rpm and direction of rotation correct? 3) Is the oil temperature abnormally high? 4) Is the temperature of the piston motor case abnormally high? 5) Are there any abnormal sounds or vibrations? 6) Are there any other abnormalities?

ASM-17-22-002

Issued 08-2008

Copyright © 8019-36 6 Maintenance Standards Replace each part according to the table below. 1 Motor section Name of part

Piston assembly

Maintenance standards 1. If there are deep scratches on the sliding section, or the sliding section is rough. 2. If the gap between the cylinder block bore and the piston assembly is too large. Upper limit of diameter clearance: 0.04 mm 3. If the shoe ball section is too loose. Maximum play (distance): 0.4 mm

Thrust plate Retainer holder Retainer plate

If there are deep scratches on the sliding sections, or the sliding sections are rough.

Valve plate Brake piston

( *2. parking brake specifications only)

Cylinder block

1. If there are deep scratches on the sliding section, or the sliding section is rough. 2. If there is abnormal wear or breakage on the engaging surfaces.

Disk

( *2. parking brake specifications only) 1. If there are deep scratches or peeling on the disk (abrasive material). 2. If there is abnormal wear or breakage on the engaging surfaces.

Ball bearing

1. If there is flaking or peeling on the rolling surfaces. 2. If there are impressions on the rolling surfaces. 3. If bearing rotations are abnormal (noises, irregular rotations).

Spring

If there is breakage or serious deformation.

O-ring

If there are scratches causing oil leakage, scratches compromising seal performance, or it is permanently deformed.

ASM-17-22-002

Issued 08-2008

Copyright © 8019-37 2 Reduction gear section Name of part

Maintenance standards

Pinion shaft

If there is abnormal damage, wear or flaking on gear tooth surfaces. *Always replace as a housing assembly.

Plate

If there is abnormal damage or wear.

Tapered roller bearing

1. If there are scratches, impressions or flaking on the roller or race section. 2. If it does not rotate smoothly without unusual noise. *Always replace as a housing assembly.

Oil seal

1. If there is damage, deformity or abnormal wear on the lips. 2. If lips have become hard.

Housing Holder Drive gear Sun gear

If there are scratches, wear or flaking on gear tooth surfaces. *Always replace as a housing assembly.

Inner race

If there are scratches, wear or flaking on the rolling surfaces of the needle bearing.

Needle bearing

If there are scratches, wear or flaking on the rolling surfaces of the needle bearing.

Planetary gear

1. If there are scratches, wear or flaking on gear tooth surfaces. 2. If there are scratches, wear or flaking on rolling surfaces of the needle bearing.

Thrust plate

If there are scratches, wear or seizure on sliding surfaces.

3 Valve section Name of part


Piston (relief valve section) Case

1. If there are deep scratches or roughness on the sliding section. 2. If the clearance between the piston and the case hole is too large. Upper limit of diameter clearance: 0.04 mm

Valve body Spool (Hydraulic timer valve)

(*3. hydraulic timer specifications only) 1. If there are deep scratches or roughness on the sliding section. If the clearance between the spool and the valve body hole is too large. 2. Upper limit of diameter clearance: 0.04 mm

Spring

If there is breakage or serious deformation.

Plug Check valve O-Ring Backup ring


4 Other Name of part


Other plugs and O-rings


ASM-17-22-002

Issued 08-2008

Copyright © 8019-38 7 Exploded views

1-1 1-38 1-6 1-8 1-5 1-7 1-4 1-3 1-2

1-26

1-36 1-18 1-35 1-17 1-16 1-15 1-14 1-13 1-12 1-11 1-10 1-9

1-37 A 1-24 1-23 1-22 1-21 1-20 1-19

1-25

AQ22002-073

ASM-17-22-002

Issued 08-2008


2-14

2-13

2-12

2-5 2-4 2-3 3

2-24 2-1

2-19 2-21 2-20 2-17

A 2-18

2-22 2-23

2-15

2-10 2-9 2-8 2-7 2-6

2-16

2-34

2-11

-5

-8

-7

-2 2-27

-3 -4

-1

2-39

2-34

-5 10

-2

2-34

-8 -6

-3

-1

11

-11

-10

-9

2-34

-4

-2

2-46 2-27

-6

2-38 2-29

2-27

-12

2-33

2-27

-2

-7 -15 2-28 2-30

2-31

-16

-8

2-34

2-45

2-32

-3

-5

-13

-5

-4

-3 2-27

-3

-2

-18

-6 -17

-10 -1

-6 2-27

-4

-5

-9 -10

-8 -11

-12

-7 -13 -14 AQ22002-074

ASM-17-22-002

Issued 08-2008

ASM-17-22-002

3

2-45 2-46

2-33

-3

-5

2-31

-8

-2

-1

-6

-2

-7

2-31

-5

-4

2-3

-4

2-27 -3

-12 -13

-8

-6

2-2

-1

2-4

2-1

2-27-7

-10

-9

2-34

2

2

-11

-19

-22

-23

-30

-11

-39

-38

-34

-28

-9

-7

11

10

-10

-8

-29

-6

-32

-17 -18

-24 -21 -20

2

-1

-4

-3

2

-16 -41 -40 -13 -14 -12

-5

-2

-3

-15 -16

-5

-10 -9

-1 -18 -17 -4

-8

-37 -22 -21 -23 -20

-24

-10

-7

-19 -16

-6

1

-17

-12

-26

-25 -14 -15 -13 -12

1

-14

-13

-11

-18

-11

-35 -36

2-27-6

-10

-9

-6

-5

-4

-3

-2

-7

-1

-8 1

Copyright ©

8019-40

8 Stracture drawing

AQ22002-075

Issued 08-2008


Q’ty

No.

Q’ty

No.

Reduction gear

1

2-10

Snap ring

1

2-28

Ball bearing

1

1-1

Housing

1

2-11

Pin

3

2-29

Pin

1

1-2

Pinion shaft

1

2-12

Retainer plate

1

2-30

Valve plate

1

1-3

Coller

1

2-13

Reainer holder

1

2-31

Pin

2

1-4

Plate

1

2-14

Piston assembly

9

2-32

Pin

2

1-5

Plate

1

2-16

Friction plate

1

2-33

Hex. socket bolt

4

1-6

Taper roller bearing

1

2-17

Coller

1

2-34

Valve assembly

1

1-7

Oil seal

1

2-18

O-ring

1

2-34-1

Body

1

1-8

Taper roller bearing

1

2-19

Brake piston

1

2-34-2

Check valve assembly

2

1-9

Plate

1

2-20

O-ring

1

2-34-2-1

Check valve

1

1-10

Coller

1

2-21

O-ring

1

2-34-2-2

Valve

1

1-11

Holder

1

2-22

Spring

12

2-34-2-3

Spring

1

1-12

Thrust washer

4

2-23

Spring

8

2-34-2-4

Plug

1

1-13

Inner race

4

2-24

O-ring

1

2-34-3

Spring

2

1-14

Needle bearing

4

2-27-1

Cover

1

2-34-4

Sleeve

1

1-15

Planetary gear

4

2-27-2

Poppet

2

2-34-5

Plug

2

1-16

Thrust plate

1

2-27-3

Plug

2

2-34-6

Orifice

2

1-17

Screw

4

2-27-4

O-ring

2

2-34-7

Plug

2

1-18

Sun gear

1

2-27-5

Spring

2

2-34-8

O-ring

4

1-19

Holder

1

2-27-6

Relief valve assembly

2

2-34-9

Filter

1

1-20

Thrust washer

3

2-27-6-1

Relief housing

1

2-34-10

Washer

1

1-21

Inner race

3

2-27-6-2

Poppet

1

2-34-11

Orifice

1

1-22

Needle bearing

3

2-27-6-3

Poppet seat

1

2-34-12

Plug

2

1-23

Planetary gear

3

2-27-6-4

Spring seat

1

2-34-13

O-ring

2

1-24

Thrust plate

1

2-27-6-5

Spring

1

2-38

O-ring

3

1-25

Drive gear

1

2-27-6-6

Plug

1

2-39

Hex. socket bolt

3

1-26

Snap ring

1

2-27-6-7

O-ring

1

2-40

Disk

4

1-35

Plug

1

2-27-6-8

Piston

1

2-41

Friction plate

2

1-36

O-ring

1

2-27-6-9

O-ring

1

2-45

Plug

1

1-37

O-ring

1

2-27-6-10

Backup ring

2

2-46

O-ring

1

Piston motor

1

2-27-6-11

Spring guide

1

3

Hex. socket bolt

4

2-1

Case

1

2-27-6-12

O-ring

1

2-3

Ball bearing

1

2-27-6-13

Set screw

1

2-4

Shaft

1

2-27-6-14

Nut

1

2-5

Thrust plate

1

2-27-6-15

O-ring

1

2-6

Cylinder block

1

2-27-6-16

Backup ring

1

2-7

Coller

1

2-27-6-17

O-ring

1

2-8

Spring

1

2-27-6-18

Backup ring

1

2-9

Coller

1

2-27-7

Orifice

1

1

2

Part name

ASM-17-22-002

Part name

Part name

Q’ty

Issued 08-2008


2 Anti-reverse valve 1 Troubleshooting If any problems occur during operation, refer to the troubleshooting table shown below to determine the cause of the problem and measures for remedying it. Troubleshooting table Problem

Cause

Remedy

1. Malfunction in something other than the piston motor, valve unit or antireverse valve.

Check to see if the oil pressure at the entry side of the valve is correct. Then inspect/repair each device.

2. Faulty seat in check valve assembly.

1. Motor does not rotate or rotates slowly.

1) Foreign substances present.

Remove foreign substances completely and repair where damaged. Clean and reassemble. Replace if scratches are deep and leak is large.

2) Excessive torque on anti-reverse valve bolts.

Fasten bolts to specified torque.

3. Faulty sleeve 1) Foreign substances present.


1. Faulty seat in check valve assembly.

2. Motor does not stop, or takes a while to stop.



2) Excessive torque on anti-reverse valve bolts.

Fasten bolts to specified torque.

2. Faulty valve inside check valve assembly. 1) Foreign substances present.

Remove foreign substances completely and repair where damaged. Clean and reassemble. Replace if sliding section is scratched

2) Valve orifice is blocked with dirt or dust.

Remove dirt or dust completely. Clean and reassemble.

3. Faulty sleeve 1) Foreign substances present.


1. Faulty valve inside check valve assembly.

3. Greater than usual shock at swing stops

ASM-17-22-002


Remove foreign substances completely. Clean and reassemble. Replace if sliding section is scratched

2) Valve orifice is blocked with dirt or dust.

Remove dirt or dust completely. Clean and reassemble.

2. Orifice is blocked with dirt or dust. 1) Orifice section of anti-reverse valve is blocked with dirt or dust.

Remove all dirt or dust. Clean and reassemble.

2) Orifice on valve unit side is blocked with dirt or dust.

Remove all dirt or dust. Clean and reassemble.

Issued 08-2008


2 Tools used No

Name

1

Location used

Remarks

Orifice (-7)

Torque setting: 2.45 Nm

Orifice (-22)


3

Plug (-5) Plug (-8)


4

Orifice (-7)

Width across flats: 2.5 mm

Orifice (-22)

Width across flats: 3 mm

Plug (-8)

Width across flats: 8 mm

Plug (-5)

Width across flats: 22

2

5

Torque wrench

Hexagonal bits

6 7

Socket for socket wrench

3 Disassembling instructions 1 Precautions prior to disassembly 1 Remove mud and dirt from exterior surfaces completely. (Wash exterior surfaces thoroughly.) 2 Drain hydraulic oil from the valve unit body and the port oil passages. 3 Select a dirt-free area for work. Use caution to prevent any mud or dirt from getting on parts. 4 Handle parts carefully to avoid dropping them, or denting or scratching them by contact. 2 Disassembly Disassemble the valve following the procedure below: 1 Removing the anti-reverse valve Loosen socket head bolts and remove the antireverse valve from the motor. (See the instruction manual for the motor.) 2 Disassembling the anti-reverse operating section 1) Remove plug (-5) and pull out spring (-3). Tools required - Socket (No. 6) - Torque wrench (No. 3)

-5

-3

AQ22002-076

2) Remove check valve assembly (-2).

-2

AQ22002-077

ASM-17-22-002

Issued 08-2008

Copyright © 8019-44 3) Remove check valve assembly (-4).

-4

AQ22002-078

3 Removing the orifice

-7

-8

Remove plug (-8) and orifice (-7). Tools required: - Hexagonal bits (No. 4, 6) - Torque wrench (No. 1, 3)

AQ22002-079

4 Assembling instructions 1 Precautions prior to reassembly 1 Clean each part with clean mineral oil and dry with air. 2 Handle cleaned parts carefully to keep them from getting dirty, dented or scratched. 3 Replace all seals with new ones. 4 Fasten all tightened parts to the specified torque. 5 Apply grease to seals before installing. 6 Once filters are removed, they cannot be reused. They must be replaced with new filters. 2 Assembly Reassemble the valve following the procedure below: 1 Installing the orifice 1) Install filter (-20) and washer (-21) Fasten orifice (-22) to the specified torque. Tools required: - Hexagonal bits (No. 5) - Torque wrench (No. 2) NOTE: Once filters are removed, they cannot be reused. -20 -21

-22 AQ22002-080

ASM-17-22-002

Issued 08-2008

Copyright © 8019-45 2) Fasten orifice (-7) and plug (-8) to the specified torque. Tools required: - Hexagonal bits (No. 4, 6) - Torque wrench (No. 1, 3)

-7

-8

AQ22002-081

2 Reassembling the anti-reverse operating section 1) Install sleeve (-4).

-4

AQ22002-082

2) Install check valve assembly (-2). -2

AQ22002-083

3) Attach O-ring (-13) to plug (-5). Insert spring (-3) into plug and fasten to specified torque.

-5

-13

-2

-3

Tightening Torque: 61.8 N·m (6.3 kgf·m) NOTE: Handle carefully so that the spring does not fall out during installation of the plug. Tools required: Socket (No. 7) Torque wrench (No. 3) Reassembly of the anti-reverse valve has now been completed. Refer to the instruction manual of the motor for motor installation procedures.

ASM-17-22-002

AQ22002-084

Issued 08-2008

Copyright © 8019-46 5 Anti-reverse valve: Exploded view

-8

-13 -22 -7 -21 -20

-1 -5 -4

-13

-2

-3 -2

-3 -13 -5

ASM-17-22-002

AQ22002-085

Issued 08-2008

Copyright ©

Section 8020

CNH



8020

HYDRAULIC FUNCTIONS

Copyright © 8020-2

TABLE OF CONTENTS HYDRAULIC FUNCTIONS.............................................................................................................................................. 3 List of functions ........................................................................................................................................................... 3 HYDRAULIC COMPONENTS LIST ................................................................................................................................ 5 CONTROL VALVE CONFIGURATION TABLE............................................................................................................... 6 Overview .................................................................................................................................................................... 6 TRAVEL CIRCUITS ....................................................................................................................................................... 8 1. Travel Low-speed Circuit ....................................................................................................................................... 8 2. Travel High Speed Circuit .................................................................................................................................... 10 3. Straight Travel Circuit (Boom-up and Travel Forwar) .......................................................................................... 12 SWING CIRCUITS ....................................................................................................................................................... 14 1. Swing Parking Circuit ........................................................................................................................................... 14 Swing Override Throttle Circuit ................................................................................................................................ 16 BUCKET CIRCUIT (CX80) ........................................................................................................................................... 18 1. Bucket Opening Circuit ........................................................................................................................................ 18 2. Bucket Closing Circuit .......................................................................................................................................... 19 BOOM CIRCUITS ........................................................................................................................................................ 20 1. Boom-up 2-speed Circuit ..................................................................................................................................... 20 2. Boom-down Load Holding Valve Circuit ............................................................................................................... 22 BOOM SWING CIRCUIT (CX80) ................................................................................................................................. 24 Boom-Swing Circuit .................................................................................................................................................. 24 BLADE CIRCUITS (CX80) ........................................................................................................................................... 26 Blade Circuits ........................................................................................................................................................... 26 ARM CIRCUITS ........................................................................................................................................................... 28 1. Arm-in / Arm-out 2-speed Circuit .......................................................................................................................... 28 BACKUP CIRCUITS ..................................................................................................................................................... 30 Breaker and Crusher Circuit (2-speed confluence crusher circuit) .......................................................................... 30 Breaker and Crusher Circuit (backup line holding valve) ......................................................................................... 32 Breaker and Crusher Circuit (breaker circuit) Ultra Small Tail Swing Hydraulic Excavator ..................................... 34 Backup Reciprocating Circuit (ultra small swing hydraulic excavator) ..................................................................... 36 Secondary Backup Reciprocating Circuit (ultra small tail swing hydraulic excavator) ............................................. 38


Issued 03-08

Copyright © 8020-3

HYDRAULIC FUNCTIONS List of functions Functions

Description

Pages

Travel Circuits Low-speed Travel circuit

Low speeds can be achieved by setting the two-stage incline angle of the travel motor to the larger angle.

Page 8-9

High-speed Travel circuit

High speeds can be achieved by setting the two-stage incline angle of the travel motor to the smaller angle. The load pressure for travel motor will automatically switch speeds to low when necessary.

Page 10-11

Straight-travel circuit

Straight travel is maintained in spite of attachment/swing operations during travel.

Page 12-13

Swing Circuits

Swing parking circuit

1.While the swing lever is positioned at neutral, the swing parking will be activated to fully hold the swing. 2.Shifting through the swing lever will release the mechanical brake to start the 3.normal swing operation. The swing parking will also stay released if attachments such as boom, arm and bucket were operated following the swing operation. The swing parking will be activated 5 s after the swing lever is put in neutral or the attachment movement is stopped.

Page 14-15

Swing override throttle circuit

Swing pushing is obtained by the swing override throttle integrated in the control valve.

Page 16-17

Super shockless relief valve

The valve is installed in the swing motor. It is designed to moderate shocks at start-ups and stops by the two-stage relief valve that comes with a time-lag feature.

Swingback Cushion Valve

An anti-reverse valve is installed in the swing motor. The valve works to reduce the backlash occurrences when the swing brake is applied. Cushion valves work to moderate shocks. They are equipped on the swing pilot line. Bucket Circuits (CX80)

Bucket-opening

Opens the bucket by switching the bucket spool

Page 18

Bucket-closing

Closes the bucket by switching the bucket spool

Page 19

Boom Circuits Boom-up 2-speeds circuit

Switch-over of boom (2) spools enables the internal confluence, thus achieving higher speeds.

Page 20-21

Boom-down load holding valve circuit

1.The boom-down movement will be enabled by releasing the load holding valve integrated in the control valve. 2.The bleed-off circuit works to control high pressures. It also reduces windage..

Page 22-23

Boom Swing Circuits (CX80) Boom Swing

Swing the boom by switching the boom swing spool

Page 24-25

Blade Circuits (CX80) Blade Operation

Operating the blade by switching the blade spool

Page 26-27

Arm Circuits Arm-in/arm-out 2-speeds circuit

1. Switch-over of arm (2) spools enables the internal confluence, thus achieving higher speeds.


Page 28-29

Issued 03-08

Copyright © 8020-4 Functions

Description

Pages

Backup circuits Breaker and Crusher circuit Backup circuit (small tail swing excavator)

Page 30-31 A backup section is provided in the main control valve as a standard feature to accommodate special attachments such as a breaker and a crusher.

Page 34-35

Backup circuit An additional backup section can be added as an option to accommodate special (ultra small swing attachments such as a slide arm excavator)

Page 36-37

Secondary circuit A secondary backup section can be added as an option to accommodate special (small tail swing attachments such as a rotating fork. excavator)

Page 38-39

Other Cushion Valve

Cushion valves work to moderate shocks. They are installed on the boom pilot line.

NOTE: See the tables page 6 for the relationship between each specification and the optional equipment.


Issued 03-08

Copyright © 8020-5

HYDRAULIC COMPONENTS LIST NOTE: See hydraulic schematic at the end of this document. 1. 2. 4. 5. 6. 10. 15. 16. 21. 22. 23. 27. 28. 29. 30. 32. 38. 42. 44. 51. 53. 54. 55. 60. 72. 75. 76. 78. 79. 82. 83. 85. 86. 93. 94. 95. 96. 97. 98. 99. 100. 101. 102. 103. 104. 114. 115. 116. B22. B26. B27. B45. Y2. Y3. Y4. Y9.

HYDRAULIC RESERVOIR BREATHER BY-PASS VALVE SCREEN FILTER RETURN FILTER MAIN HYDRAULIC PUMP MAIN CONTROL VALVE HYDRAULIC SWIVEL TRAVEL MOTOR SWING MOTOR TRAVEL MOTOR BRAKE DIPPER CYLINDER BUCKET CYLINDER BOOM SAFETY VALVE DIPPER SAFETY VALVE BOOM LOAD HOLDING VALVE HBCV DOZER BLADE OIL COOLER OIL COOLER BY-PASS VALVE ACCUMULATOR BOOM & BUCKET CONTROL LEVER SWING & DIPPER CONTROL LEVER TRAVEL CONTROL PEDAL PILOT SYSTEM MANIFOLD CONTROL PEDAL (OPTIONAL) FLOW RE-INJECTION BLOCK (OPTIONAL) 3-WAY SELECTOR (OPTIONAL) RETURN FILTER (OPTIONAL) CONTROL SHUTTLE BLOCK (OPTIONAL) PILOT CIRCUIT FILTER SHUT-OFF VALVE (OPTIONAL) HAND/FOOT CONTROL PILOT FILTER PILOT FILTER BY-PASS VALVE PILOT CIRCUIT SUPPLY MANIFOLD PILOT CIRCUIT RETURN MANIFOLD BOOM/DIPPER PILOT CIRCUIT MANIFOLD SWING PILOT CIRCUIT CUSHION VALVE HYDRAULIC BREAKER FOOT CONTROL OFFSET BACKHOE FOOT CONTROL DOZER BLADE HAND CONTROL DOZER BLADE CYLINDER OFFSET BACKHOE CYLINDER 3 ELECTROVALVE BLOCK BOOM CYLINDER BOOM PILOT CIRCUIT CUSHION VALVE BOOM FOOT DIRECTION CONTROL PEDAL BOOM FOOT POSITIONING PILOT SHOCK ABSORBER BOOM FOOT STEERING CYLINDER SWING PILOT PRESSURE SWITCH UPPER PILOT PRESSURE SWITCH (YELLOW BAND) TRAVEL PILOT PRESSURE SWITCH OVERLOAD INDICATOR PRESSURE SWITCH PILOT PRESSURE SOLENOID VALVE (BLUE BAND) SWING BRAKE SOLENOID VALVE (PINK BAND) 2 STAGE TRAVEL SOLENOID VALVE (RED BAND) CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE Y25. OPTION 2 SOLENOID VALVE (RED BAND) Y26. OPTION 2 SOLENOID VALVE (BLUE BAND)


Issued 03-08

Copyright © 8020-6

CONTROL VALVE CONFIGURATION TABLE Overview Control valves are configured as follows according to model and specification. MONO BOOM with BLADE (CX75SR)

MONO BOOM with BLADE (CX80)

Blade

Blade

PT

PT Boom Swing

Standard

OFFSET BOOM with BLADE (CX75SR) (Specification for Europe)

Blade PT

Buckup Offset

Buckup

Secondary backup Blade

Secondary backup Blade

Buckup

Boom Swing Option Buckup


PT

PT

PT

Optional

Blade

Offset

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Copyright © 8020-7

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Issued 03-08

Copyright © 8020-8

Travel Circuits 1. Travel Low-speed Circuit The travel patterns are normal. Turning the key OFF once and switching it back ON during high-speed travel will always set the speed back to low. The oil discharged from A1 enters port P1 of the control valve entry, while the oil from A2 enters into port P2 of the control valve entry. Each flow goes into the travel motor through the switch-over of the left and right travel spool. By these flows, the machine travels forward and backward. The 2-speed travel solenoid valve will be turned OFF and the hydraulic oil in port P of the travel motor will be connected to the pilot tank line.

1. 10. 15. 16. 21. 51. 55. 60. 102.

HYDRAULIC RESERVOIR MAIN HYDRAULIC PUMP MAIN CONTROL VALVE HYDRAULIC SWIVEL TRAVEL MOTOR ACCUMULATOR TRAVEL CONTROL PEDAL PILOT SYSTEM MANIFOLD 3 ELECTROVALVE BLOCK

Legend Pressure Line Tank line Pilot pressure line Pilot tank line Electric Line


Issued 03-08

Copyright © 8020-9

Travel Low-speed Circuit

21

21 16

1

15

55 51

INTERNAL CHANGEOVER SWITCH IN PANEL

MONITOR SWITCH PANEL

102

60

10


Issued 03-08


2. Travel High Speed Circuit With High-Speed Travel, high speeds can be achieved by setting the two-stage incline angle of the travel motor to the smaller angle. The circuit has a travel motor, which 5 switches over to lower speeds by utilizing load pressure on the travel motor while traveling at high speeds. The oil discharged from A1 enters port P1 of the control valve entry, while the oil from A2 enters port P2 of the control valve entry. Each flow goes into the travel motor through the switch-over of the left and right travel spool. By these flows, the machine travels forward and backward. To obtain high speeds, electronic signals are sent to the switch panel through the travel change-over switch. Then electronic signals are sent from the switch panel to the solenoid valve for 2-speed travel in the assembly valves to switch the assembly valves. This enables the original pilot pressure (4.2 MPa) {609 psi} from port C1 of the assembly valves to be connected with port P of the left and right travel motors through the rotating joint. The original pressure (4.2 MPa) {609 psi} that entered port P of the left and right travel motors positions the incline angle of the travel motor to the smaller angle, enabling faster speeds.

1. 10. 15. 16. 21. 51. 55. 60. 102.

HYDRAULIC RESERVOIR MAIN HYDRAULIC PUMP MAIN CONTROL VALVE HYDRAULIC SWIVEL TRAVEL MOTOR ACCUMULATOR TRAVEL CONTROL PEDAL PILOT SYSTEM MANIFOLD 3 ELECTROVALVE BLOCK



Issued 03-08


Travel High Speed Circuit

21 16 21

1

15

55 51

INTERNAL CHANGEOVER SWITCH IN PANEL 102

60


10


Issued 03-08


3. Straight Travel Circuit (Boom-up and Travel Forwar) The following applies when travel and boom-up operations are conducted at the same time. The hydraulic oil that entered the pilot pump from PP, which was connected to the tank via travel spool, becomes blocked off by the switch-over of travel spool. Also, the switch-over of the spool to the boom blocks off the branch channels from PP via all spools for attachments (boom, arm, bucket, swing, including offset if equipped with this), which were connected to the tank. Therefore, the hydraulic oil from the pilot pump entering through PP cannot flow any further, and the circuit pressure rises up to the original pressure of (4.2 MPa) {609 psi} . This original pressure acts on the pilot chamber of the straight travel valve and switches over the straight travel valve. The switch-over of the straight travel valve enables P1 to achieve travel and P2 to drive attachments. The left and the right pressures are equal for travel because one pump drives those motors, thus enabling straight travel. In addition, extra hydraulic oil from P2 is supplied to the travel side through a check with travel confluence throttle to keep the speed loss to a minimum. This also applies when travel and the upper actuators other than boom are operated at the same time.

1 10. 15. 16. 21. 51. 55. 60. 102. 103. 104.

HYDRAULIC RESERVOIR MAIN HYDRAULIC PUMP MAIN CONTROL VALVE HYDRAULIC SWIVEL TRAVEL MOTOR ACCUMULATOR TRAVEL CONTROL PEDAL PILOT SYSTEM MANIFOLD 3 ELECTROVALVE BLOCK BOOM CYLINDER BOOM PILOT CIRCUIT CUSHION VALVE



Issued 03-08


Straight Travel Circuit (Boom-up and Travel Forward)

21 16 21

1

103

55

15

51

104

INTERNAL CHANGEOVER SWITCH IN PANEL



102

60

10

Issued 03-08


Swing Circuits 1. Swing Parking Circuit Once the engine is turned on and the swing lever is positioned in neutral, the swing brake solenoid valve will be turned ON (SH75: 12V, SH135: 24 V) and the swing parking brake will be activated. When the swing pressure switch is turned ON by the shifting of the lever, the output to the swing brake solenoid valve from the switch panel will be turned OFF. This releases the swing parking brake and enables the swing operation. In another case, if an attachment such as an arm is moved within 5 s after the swing lever was returned to neutral, a lateral force will be generated for the swing movement. In order to prevent the dragging caused by braking, the parking bake will also be released. Once the signals from attachment pressure switch (2.0 MPa {290 psi} : ON, 1.5 MPa {218 psi} : OFF) are sent to the switch panel and the output to swing brake solenoid valve from switch panel is turned OFF, the swing parking brake will be released. 5 s after the swing pressure switch and the attachment pressure switch are turned OFF, the solenoid valve will be turned ON, enabling the swing parking brake to operate.

Key switch

Swing pressure switch

Attachment pressure switch

Swing brake solenoid valve

Swing motor mechanical brake

OFF

OFF

OFF

OFF

ON*

Key Switch OFF

ON

OFF

OFF

ON

ON

Key Switch ON

ON

OFF

ON

ON

ON

Attachment operations

ON

ON

ON

OFF

OFF

Independent operation of swing

ON

ON

ON

OFF

OFF

Attachment + swing operation

ON

OFF

OFF

ON (in 5 s)

ON

Attachment in neutral

Remarks

Notes: • The attachment pressure switch will be ON when the spool is switched over for either boom, arm, bucket or swing (including offset if equipped with this) and activates the original pilot pressure. • When an asterisk (*) accompanies the “swing motor mechanical brake ON” statement, it indicates that the swing parking release pressure automatically returns to the tank pressure because all else is OFF, which in turn activates the mechanical brake. 1 10. 15. 22. 51. 60. 96. 102.

HYDRAULIC RESERVOIR MAIN HYDRAULIC PUMP MAIN CONTROL VALVE SWING MOTOR ACCUMULATOR PILOT SYSTEM MANIFOLD SWING PILOT CIRCUIT CUSHION VALVE 3 ELECTROVALVE BLOCK



Issued 03-08


Swing Parking Circuit (independent operation of swing)

22

1

15


51

102 96

60

SWING BRAKE SOLENOID VALVE 10


Issued 03-08


Swing Override Throttle Circuit Providing an override throttle on the parallel circuit enables the pressure to rise at combined operation of arm and swing, thus securing the swing force for press digging operation.

1 10. 15. 22. 27. 51. 60. 96. 102.

HYDRAULIC RESERVOIR MAIN HYDRAULIC PUMP MAIN CONTROL VALVE SWING MOTOR DIPPER CYLINDER ACCUMULATOR PILOT SYSTEM MANIFOLD SWING PILOT CIRCUIT CUSHION VALVE 3 ELECTROVALVE BLOCK



Issued 03-08


Swing Override Throttle Circuit

22

27

1

SWING OVERRIDE FIXED THROTTLE

15 000

51

102

60

96

SWING BRAKE SOLENOID VALVE 10


Issued 03-08


Bucket Circuit (CX80) 1. Bucket Opening Circuit When the bucket control lever is moved to the opening side, the pilot pressured oil is supplied to Port pb7 of the control valve. The bucket spool will be in a preparation state. The hydraulic pressured oil delivered from the hydraulic pump A1 is supplied to a bucket spool through a center bypass oil circuit also it is supplied to the rod side of a bucket cylinder. Accordingly, the bucket opens by contraction of the rod of the bucket cylinder. The returned oil from the bucket cylinder bottom runs into the tank oil circuit through a bucket spool. 1 10. 15. 28. 51. 53. 102.

HYDRAULIC RESERVOIR MAIN HYDRAULIC PUMP MAIN CONTROL VALVE BUCKET CYLINDER ACCUMULATOR BOOM & BUCKET CONTROL LEVER 3 ELECTROVALVE BLOCK



Issued 03-08


2. Bucket Closing Circuit

1

28

102

51

15

53

10


Issued 03-08


Boom Circuits 1. Boom-up 2-speed Circuit The oil discharged from A1 is supplied to the boom (2) spool through the parallel oil passage via the right travel spool or the straight travel valve, and merges at the downstream of the boom (1) spool. The oil discharged from A2 merges with the oil discharged from boom (2) by way of parallel oil passage and the boom (1) spool, and flows into the bottom side of the boom cylinder via holding valve.

1 10. 15. 51. 60. 102. 103. 104.

HYDRAULIC RESERVOIR MAIN HYDRAULIC PUMP MAIN CONTROL VALVE ACCUMULATOR PILOT SYSTEM MANIFOLD 3 ELECTROVALVE BLOCK BOOM CYLINDER BOOM PILOT CIRCUIT CUSHION VALVE



Issued 03-08


Boom-up 2-speed Circuit

1

103

15

104

51

102

60

10


Issued 03-08


2. Boom-down Load Holding Valve Circuit The boom-down pilot pressure goes into port Pb8 of the control valve and the main control valve spool moves to the left. Also, the pilot pressure enters Port Pc2 and moves the load holding valve spool to the left. Through this movement, the oil in the spring chamber of the load holding valve check passes the load holding valve spool, creating a connection to the tank. As a result, the pressure on the spring chamber decreases and the load holding valve check will be released. The pressurized oil on the boom cylinder bottom side returns to the tank line as the load holding valve opens. As a result, the boom cylinder rod retracts and the boom is lowered. Also, the bleed-off circuit controls high pressures, which in turn reduces windage.

1 10. 15. 32. 51. 60. 102. 103. 104.

HYDRAULIC RESERVOIR MAIN HYDRAULIC PUMP MAIN CONTROL VALVE BOOM LOAD HOLDING VALVE ACCUMULATOR BOOM & DIPPER CONTROL SHOCK ABSORBER 3 ELECTROVALVE BLOCK BOOM CYLINDER BOOM PILOT CIRCUIT CUSHION VALVE



Issued 03-08


Boom-down Load Holding Valve Circuit TO TANK LINE

LOAD HOLDING VALVE SPOOL BOOM-DOWN PILOT LINE

32

BOOM CYLINDER BOTTOM SIDE DETAIL

BLEED-OFF CIRCUIT

1

103

15 104

51

102

60

10


Issued 03-08


Boom Swing Circuit (CX80) Boom-Swing Circuit As the boom swing remote control valve is switched over, the pilot oil enters Port prb1 or pra1. The oil at P2 from the hydraulic pump then flows into the boom swing cylinder via Port BR1 or AR1 through the boom swing valve. The returning oil flows into the tank through Port AR1 or BR1. 1 10. 15. 51. 102. 114. 115. 116.

HYDRAULIC RESERVOIR MAIN HYDRAULIC PUMP MAIN CONTROL VALVE ACCUMULATOR 3 ELECTROVALVE BLOCK BOOM FOOT DIRECTION CONTROL PEDAL BOOM FOOT POSITIONING PILOT SHOCK ABSORBER BOOM FOOT STEERING CYLINDER



Issued 03-08


Boom-Swing Circuit

1 116 103

1 115

114

15

104

51 102

102

60

15

10

51

10


Issued 03-08


Blade Circuits (CX80) Blade Circuits As the blade remote control valve is switched over, the pilot oil enters Port prb2 or pra2. The oil at PR5 from the gear pump then flows into the blade cylinder through the Parallel passage. The returning oil flows into the tank through Port AR2 or BR2. 1 10. 15. 51. 99. 100. 102.

HYDRAULIC RESERVOIR MAIN HYDRAULIC PUMP MAIN CONTROL VALVE ACCUMULATOR DOZER BLADE HAND CONTROL DOZER BLADE CYLINDER 3 ELECTROVALVE BLOCK



Issued 03-08


Blade Circuit

100

1

103

1

15

104

51

99

102

60

15

10

102

51

10


Issued 03-08


Arm Circuits 1. Arm-in / Arm-out 2-speed Circuit The oil discharged from A1 is supplied to the arm (1) spool via parallel oil passage through central bypass oil passage or straight travel spool. TheArm-in / Arm-out 2-speed circuit has a configuration where the discharged oil from A2 is supplied to the arm (2) spool through the central bypass oil passage or parallel oil passage to merge at the upstream of the arm (1) spool. The returning oil from the cylinder will be allowed to merge with the oil on the supply side through self regeneration only when the arm is in (when the pressure of oil on the supply side becomes lower than the pressure of oil returning). 1 10. 15. 27. 51. 60. 102.

HYDRAULIC RESERVOIR MAIN HYDRAULIC PUMP MAIN CONTROL VALVE DIPPER CYLINDER ACCUMULATOR PILOT SYSTEM MANIFOLD 3 ELECTROVALVE BLOCK



Issued 03-08


Arm-in / Arm-out 2-speed Circuit

Arm-In Self Regeneration

27

1

15

51

102

60

10

NOTE: INDICATES THAT AN ARM-OUT OPERATION IS TAKING PLACE


Issued 03-08


Backup Circuits Breaker and Crusher Circuit (2-speed confluence crusher circuit) The solenoid valve will be turned ON by turning the switch inside the cab toward the crusher side. By stepping on the backup pedal, the pilot pressure from the remote control valve passes through the solenoid valve via shuttle valve and enters Port P of the holding valve and Port Pb2 of the backup (2) spool. The backup (2) spool moves to the right and shuts off the central bypass. The pilot pressure from the solenoid valve acts on Port pcc of the confluence spool and moves the spool to the left to shut off the central bypass. The oil in Port P2 thus flows into the holding valve through Port P3 of the control valve. The holding valve acts on the holding valve release spool by communicating the pilot pressure from the solenoid valve to Port P. The valve thus returns the oil in the spring chamber to the tank and releases the check in the holding valve. The oil at Port P3 of the control valve enters Port P4, which is upstream of the control valve backup spool, through the holding valve check. It then merges with the oil from P1. 1 10. 15. 51. 60. 72. 75. 76. 78. 79. 85. 102. Y9.

HYDRAULIC RESERVOIR MAIN HYDRAULIC PUMP MAIN CONTROL VALVE ACCUMULATOR PILOT SYSTEM MANIFOLD CONTROL PEDAL (OPTIONAL) HAMMER/CRUSHER SELECTOR HAMMER/CRUSHER SELECTOR RETURN FILTER (OPTIONAL) CONTROL SHUTTLE BLOCK (OPTIONAL) HAND/FOOT CONTROL PILOT FILTER 3 ELECTROVALVE BLOCK CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE



Issued 03-08


Breaker and Crusher Circuit (2-speed confluence crusher circuit) 72

85 Y9 79 1

75

SWITCH LOCKER

15

51

76

60 102 78

10


Issued 03-08


Breaker and Crusher Circuit (backup line holding valve)

Hold-Release Spool

Holding Valve Check


Issued 03-08


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Issued 03-08


Breaker and Crusher Circuit (breaker circuit) Ultra Small Tail Swing Hydraulic Excavator By turning the switch in the cab to the breaker side and stepping on the pedal, the pilot pressure, which entered Pb2 in the control valve, switches over to the backup spool. As a result, the pressurized oil from A1 will be supplied to the breaker through the direction valve.

1 10. 15. 51. 60. 72. 76. 78. 79. 85. 102. Y9.

HYDRAULIC RESERVOIR MAIN HYDRAULIC PUMP MAIN CONTROL VALVE ACCUMULATOR PILOT SYSTEM MANIFOLD CONTROL PEDAL (OPTIONAL) HAMMER/CRUSHER SELECTOR RETURN FILTER (OPTIONAL) CONTROL SHUTTLE BLOCK (OPTIONAL) HAND/FOOT CONTROL PILOT FILTER 3 ELECTROVALVE BLOCK CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE



Issued 03-08


Breaker and Crusher Circuit (breaker circuit) Ultra Small Tail Swing Hydraulic Excavator 72

85

1

79

Y9

15

51

76

102

60

78

10


Issued 03-08


Backup Reciprocating Circuit (ultra small swing hydraulic excavator) As the back up remote control valve is switched over, the pilot oil enters Port pra1 or Port prb1. The oil at P2 then flows into the backup valve AR1 or Port BR1 through the parallel passage. The returning oil flows into the tank through Port BR1 or Port AR1.

1 10. 15. 51. 60. 83. 85. 98. 102.

HYDRAULIC RESERVOIR MAIN HYDRAULIC PUMP MAIN CONTROL VALVE ACCUMULATOR PILOT SYSTEM MANIFOLD SHUT-OFF VALVE (OPTIONAL) HAND/FOOT CONTROL PILOT FILTER OFFSET BACKHOE FOOT CONTROL 3 ELECTROVALVE BLOCK



Issued 03-08


Backup Reciprocating Circuit (ultra small swing hydraulic excavator) 98

85 1

15

83 51

102

60

10


Issued 03-08


Secondary Backup Reciprocating Circuit (ultra small tail swing hydraulic excavator) As the backup remote control valve is switched over, the pilot oil enters Port prb3 or Port pra3. The oil at PR5 from the gear pump then flows into the backup valve BR3 or Port AR3 through the parallel passage. The returning oil flows into the tank through Port AR3 or Port BR3. Drain lines are pre-installed in the secondary backup section to accommodate special attachments such as a rotating fork.

1 10. 15. 51. 60. 83. 85. 99. 102.

HYDRAULIC RESERVOIR MAIN HYDRAULIC PUMP MAIN CONTROL VALVE ACCUMULATOR PILOT SYSTEM MANIFOLD SHUT-OFF VALVE (OPTIONAL) HAND/FOOT CONTROL PILOT FILTER DOZER BLADE HAND CONTROL 3 ELECTROVALVE BLOCK



Issued 03-08


Secondary Backup Reciprocating Circuit (ultra small tail swing hydraulic excavator)

99

1 85

15

83

51

102

60

10


Issued 03-08


NOTES .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... 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.................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... ....................................................................................................................................................................................


Issued 03-08

Copyright ©

Section 8030

CNH



8030

HYDRAULIC COMPONENT FUNCTIONS

Copyright ©

8030-2

TABLE OF CONTENTS HYDRAULIC PUMP ................................................................................................................................................. 3 Configuration and Principle of Operation ......................................................................................................... 3 Flow Control..................................................................................................................................................... 5 CONTROL VALVE ................................................................................................................................................... 7 Operation with All Spools in Neutral ................................................................................................................ 7 Independent Operation .................................................................................................................................... 9 Combined Operations .................................................................................................................................... 19 Relief Valve.................................................................................................................................................... 20 SWING UNIT .......................................................................................................................................................... 23 Functional and Operational Description......................................................................................................... 23 Overview ........................................................................................................................................................ 31 TRAVEL UNIT (CX75SR)....................................................................................................................................... 35 External Dimensional Drawing....................................................................................................................... 35 Basic Structure and Drawings........................................................................................................................ 36 Operational Description ................................................................................................................................. 39 TRAVEL UNIT (CX80)............................................................................................................................................ 51 External Dimensional Drawing....................................................................................................................... 51 Basic Structure and Drawings........................................................................................................................ 52 Operational Description ................................................................................................................................. 55


Issued 03-08

Copyright © 8030-3

HYDRAULIC PUMP Configuration and Principle of Operation The pump consists of a main pump (1), a blade pump (2) and a pilot pump (3), which are connected in series. The main pump is a swash-plate type variable displacement piston pump, which delivers two equal volumes using one cylinder block. The cylinder block has ten pistons inside. Those pistons divert and alternately deliver the oil to Delivery Ports (5 and 6). Each group of 5 pistons works as one pump.


Issued 03-08

Copyright © 8030-4

When the drive shaft (10), which is connected to the engine, rotates, the cylinder block (11) connected to the shaft via spline and the piston section (12) rotates. Since the piston section (12) is pushed towards the swash plate (14) via retainer (13), it rotates on the inclined plane of the swash plate (14) and reciprocates within the cylinder block (11) according to the incline angle of the swash plate (14). The piston (12) draws in oil while going down the inclined plane of the swash plate (14) and discharges oil while coming up. The oil from the tank is taken from the inlet port (9), which is shared by all the pumps, and is divided inside the cover (4) into the main pump (1), the blade pump (2) and the pilot pump (3). The oil to the main pump (1) passes the control plate (15) and is drawn in by the piston (12) in cylinder block (11). The oil delivered from the piston (12) is alternately divided into the passages (20, 21) in the control plate (15), and will be discharged from the delivery ports (5, 6) of each group of 5 pistons. The discharge volume of the pump fluctuates according to the changes in piston stroke in conjunction with the changes in the incline angle of the swash plate (14). The operation of the swash plate (14) is regulated by the discharge pressure in the main pump and the discharge pressure in the blade pump. (See below for details).


Issued 03-08

Copyright © 8030-5

Flow Control 1) Constant controlling of simultaneous output The pump output will be maintained at a certain level by increasing / decreasing the flow according to the pump discharge pressure. The force generated by the discharge pressure acts on the swash plate (14) via the piston section (12). The force of the discharge pressure generates a moment (return moment) to decrease the incline angle by using the difference between the center of piston and the center of incline rotation in swash plate. The return moment varies according to the discharge pressure and the incline angle.


Issued 03-08

Copyright © 8030-6

Before the incline When the discharge pressure is low, the return moment is also small and the spring (16) is not bent. Thus the swash plate (14) is at a maximum incline angle to maintain maximum discharge. After the incline When the discharge pressure increases, the return moment also increases. As a result the spring (16) is bent and the incline angle of the swash plate (14) will move to the position where the return moment and the spring force become balanced, reducing the discharge volume. As the discharge volume further increases, the incline angle decreases accordingly. The spring (17) will also start to bend to keep the volume decreasing.

2) Power-down control by discharge pressure of blade pump (blade shift) An over-torque condition of the input shaft due to the simultaneous high-pressure operations of the main pump and the blade pump is prevented by changing the output characteristics of the main pump through the discharge pressure of the blade pump. The discharge pressure on the blade pump acts on the shift piston (18) via passage (19). When the discharge pressure on the blade pump increases, the force on the shift piston increases and the moment counteracting the springs (16, 17) is generated on the swash plate (14). The moment acting on the swash plate (14) increases because extra moment generated by the shift piston force is added to the return moment which is generated by the main pump discharge pressure. Therefore, when the discharge pressure on the blade pump is high, the swash plate (14) starts its incline even if the discharge pressure on the main pump is low. Thus, an over-torque on the input shaft will not take place because the main pump output becomes low when the pressure on the blade pump is high.


Issued 03-08

Copyright © 8030-7

CONTROL VALVE Operation with All Spools in Neutral 1) Main passage The oil supplied from Port P1 passes the neutral passage (2) via passage (1) and flows through Travel (Right), Backup, Boom 2 and Arm 1 sequentially. The oil passed through Arm 1 flows into the tank passage through passage (3) to be discharged into the tank ports (T1, T2). Also, the oil supplied from Port P1 through passage (4) is directed into the parallel passage (7) through passage (6) by way of the bridge (5) and travel straight valve. Then, Backup, Swing, Boom 2, and Arm 1 sections will be communicated via each check valve and the flow will be stopped by the spools in each section. However, because the parallel passage (7) is connected with the neutral passage (2) via passage (8) and check valve, the oil will flow into the parallel passage (7) from Port P1 without passing the travel straight valve when Travel (Right) is not taking place. In the same manner, the oil supplied from Port P2 flows into the neutral passage (10) via passage (9). It then returns to the main body via the inlet section through passage (11), and flows into the tank passage through neutral cut spool via passage (12). Also, the oil supplied from Port P2 is communicated with Travel (Left), Bucket, Boom 1 and Arm 2 sections via the parallel passage (13) and check valve. The flow is stopped by the spools in each section. The oil supplied from Port PR5 (the third pump) flows in the neutral passage (27) through the inlet section passage (26). The oil passing the blade section (add-on) flows into tank 1 passage through passage (28) via the outlet section. Also, the oil supplied from Port PR5 is communicated with the blade section via parallel passage (29) and check valve, and the flow is stopped by the spool.

2) Signal passage Front control signals The oil from the hydraulic power source for signals, which enters Port PP, is directed into Port PA (Front signal) through throttle (13). It also flows into the 5-way valve side of the front control section through passage (14). It then passes passage (15), inlet section, passage (16) and the 4-way valve side of the front section, and will be discharged from passage (17) into Port DR (Drain Port). Travel control signals The oil from the hydraulic power source for signals, which enters Port PP, is directed into Port PT (Travel signal) through throttle (18). It also will be discharged from passage (17) into Port DR (Drain Port) by way of passage (20) and Travel left spool. Travel straight valve switch-over signals The oil from the hydraulic power source for signals which enters Port PP, flows from passage (22) into the travel right spool passing throttles (13, 21) to be discharged from the neck part of the spool into the tank passage. At the same time, it flows into the travel left spool through passage (23), and will be discharged from the neck part of the spool into tank passage. At this time, the oil which flows into passage (23), will be directed through the annular passage (24) into the pressure chamber (25) for switching over travel straight valve.


Issued 03-08

Lep SC75SRCX80-8030-0EN BUCKET

TRAVEL (RIGHT) TRAVEL (STRAIGHT

BACKUP TRAVEL (LEFT)

SWING

ARM 2

BOOM 2

BOOM 1

ARM 1

BLADE

Copyright ©

8030-8

Issued 03-08

Copyright © 8030-9

Independent Operation 1) Travel spool switch-over (Figure 1) Because switching the travel right spool by adding pressure to Port Pa1 (Pb1) closes the neutral passage (A) and shuts off the downstream flow, the oil supplied from Port P1 will pass the neck of the travel right spool through neutral passage (A) and will flow into cylinder Port A1 (B1). The returning oil from cylinder Port B1 (A1) passes the neck of the travel right spool and flows into the tank passage. In the same manner, because switching the travel left spool by adding pressure to Port Pa6 (Pb6) closes neutral passage (B) and shuts off the downstream flow, the oil supplied from Port P2 flows into cylinder Port A6 (B6) by way of neutral passage (B), passage (C) and the neck of the travel left spool. The returning oil from cylinder Port B6 (A6) passes the neck of the travel left spool and flows into the tank passage.

TRAVEL (RIGHT)

TRAVEL (LEFT)

2) Backup spool switch-over (Figure 2) If this section is to be used, first remove the stopper plugs on the cylinder port and on the pilot cap. Additionally, replace the shut off valve with an overload release valve and remove the stopper plug on Port P4 if necessary. Because switching the backup spool by adding pressure to Port Pa2 (Pb2) closes neutral passage (A) and shuts off the downstream flow, the oil supplied from Port P1 pushes up the check valve (1) through parallel passage (B) and flows into cylinder Port A2 (B2) by way of passage (C) and the neck of backup spool. The returning oil from cylinder Port B2 (A2) passes the neck of the backup spool and flows into the tank passage. This section can also be merged with an external source through Port P4.


Issued 03-08


3) Swing spool switch-over (Figure 3) Because switching the swing spool by adding pressure to Port Pa3 (Pb3) closes neutral passage (A) and shuts off the downstream flow, the oil supplied from Port P1 pushes up the check valve (1) through parallel passage (B) and flows into cylinder Port A3 (B3) by way of passage (C) and the neck of the swing spool. The returning oil from cylinder Port B3 (A3) passes the neck of the swing spool and flows into the tank passage.

4) Bucket spool switch-over (Figure 3) Because switching the bucket spool by adding pressure to Port Pa7 (Pb7) closes neutral passage (D) and shuts off the downstream flow, the oil supplied from Port P2 pushes up the check valve (2) through parallel passage (E) and flows into cylinder Port A7 (B7) by way of passage (F) and the neck of the bucket spool. The returning oil from cylinder Port B7 (A7) passes the neck of the bucket spool and flows into the tank passage.


Issued 03-08


5) Boom spool switch-over 1] Neutral Position (Figure 4)

The valve has an anti-drift valve installed on the cylinder bottom side of Boom 1. In the neutral position, the poppet (1) is firmly seated by the pressure on Port A7, which was directed to the spring chamber (C) through passage (A), poppet (2) and passage (B). 2] Boom-up (2-pump confluence) (Figure 5) Because switching the boom 1 spool by adding pressure to Port Pa8 closes neutral passage (A) and shuts off the downstream flow, the oil supplied from Port P2 pushes up the check valve (1) through parallel passage (B), passes passage (C) and the neck of the boom 1 spool, then pushes open the poppet (2) in the anti-drift valve and flows into cylinder Port A7. Because switching the boom 2 spool and adding pressure to Port Pa4 at the same time will close neutral passage (D) and shut off the downstream flow, the oil supplied from Port P1 pushes up the check valve (3) through parallel passage (E) and flows into cylinder port A7, by way of passage (F), neck of the boom 2 spool and passage (G). The returning oil from cylinder Port B7 passes the neck of the boom 1 spool and flows into the tank. 3] Boom-down (Figure 6) Because switching the boom 1 spool by adding pressure to Port Pb8 closes neutral passage (A) and shuts of the downstream flow, the oil supplied from Port P2 pushes up the check valve (1) through parallel passage (B) and flows into cylinder Port B7 by way of passage (C) and the neck of the boom 1 spool. Switching the boom 1 spool and adding pressure to Port pc2 at the same time in order to switch poppet (3) in the anti-drift valve will reduce the pressure in spring chamber (D) to open poppet (2). The returning oil from cylinder Port A7 will pass the neck of the boom 1 spool and flow into the tank passage.


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Issued 03-08


6) Arm spool switch-over 1] Dump (2-pump confluence) (Figure 7)

Switching the arm 1 spool by adding pressure to Port Pa5 closes the neutral passage (A). The oil supplied from Port P1 pushes up the tandem check valve (1) through neutral passage (A) and flows into cylinder Port A5 by way of passage (C) and the neck of the arm 1 spool. At the same time, part of the oil supplied from Port P1 will flows into cylinder Port A5 by way of parallel passage (B), annular restriction (D), parallel check valve (2) and passage (C). Switching the arm 1 spool and adding pressure to Port Pa9 at the same time in order to switch the arm 2 spool will close the neutral passage (E). The oil supplied from Port P2 pushes up the tandem check valve (3) through neutral passage (E) and flows into cylinder Port A5 by way of passage (G), neck of the arm 2 spool and passage (I). At the same time, part of the oil supplied from Port P2 will flow into cylinder Port A5 by way of parallel passage (F), annular restriction (H), parallel check valve (4), passage (G) and passage (I). The returning oil from the cylinder Port B5 flows into the tank passage through the neck of the arm 1 spool and also flows into the tank passage by way of passage (J) and the neck of the arm 2 spool. The annular restriction (D) works as a primary restriction for a simultaneous operation with swing movements. The annular restriction (H) works as a primary restriction for a simultaneous operation with boom. 2] Crowd (2-pump confluence) (Figure 8) Switching the arm 1 spool by adding pressure to Port Pb5 will close the neutral passage (A), and the oil supplied from Port P1 pushes up the tandem check valve (1) through neutral passage (A) and flows into cylinder Port B5 by way of passage (C) and the neck of arm 1 spool. At the same time, part of the oil supplied from Port P1 flows into cylinder Port B5 by way of parallel passage (B), annular restriction (D), parallel check valve (2) and passage (C). Switching the arm 1 spool and adding pressure to Port Pb9 at the same time in order to switch the arm 2 spool will close the neutral passage (E). The oil supplied from Port P2 pushes up the tandem check valve (3) through neutral passage (E) flows into cylinder Port A5 by way of passage (G), neck of the arm 2 spool and passage (I). At the same time, part of the oil supplied from Port P2 flows into cylinder Port B5 by way of parallel passage (F), annular restriction (H), parallel check valve (4), passage (G) and passage (I). The returning oil from cylinder Port B5 flows into the tank by way of the neck of the arm 1 spool, passage (K) and annular restriction (L). At this time, part of the returning oil pushes the check valve (5) with restriction and flows into passage (C) via passage (M), increasing the supply volume fed to cylinder Port B5 (Regenerative circuit).


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Issued 03-08


7) Blade spool switch-over (Add-on) (Figure 9) Because switching the blade spool by adding pressure to Port Pra2 (Prb2) closes the neutral passage (A) and shuts off the downstream flow, the oil supplied from Port PR5 pushes up the check valve (1) through parallel passage (B) and flows into cylinder Port AR2 (BR2) by way of passage (C) and neck of the blade spool. The returning oil from cylinder Port BR2 (AR2) passes the neck of the blade spool and flows into the tank passage.

8) Boom Swing spool switch over (Add-on) (Figure 9A) Because switching the boom swing spool by adding pressure to Port Pra1 (Prb1) closes the neutral passage (A) and shuts off the downstream flow, the oil supplied from Port PR5 pushes up the check valve (1) through parallel passage (B) and flows into cylinder Port AR1 (BR1) by way of passage (C) and neck of the boom swing spool. The returning oil from cylinder Port BR1 (AR1) passes the neck of the boom swing spool and flows into the tank passage.

9) Relief valve 1] Main relief valve (Figure 10)

The oil in Port P1 is directly connected with the inlet passage (A) of the main relief valve via common check valve (1), while the oil in Port P2 is directly connected with the inlet passage (A) of the main relief valve via common check valve (2). The main relief valve prevents the maximum pressure in pumps P1 and P2 from exceeding their programmed values. (The operational description for main relief valve is provided separately). 2] Overload relief valve In each cylinder port of Boom 1, Arm 1, Bucket and Offset, an overload relief valve is installed to prevent abnormal boosts of pressure on the actuator due to external forces. The maximum pressure will also be regulated if the programmed pressure is lower than the pressure on main relief valve. The overload relief valve also prevents cavitation by drawing oil in from the tank when the pressure on cylinder port becomes negative. Lep SC75SRCX80-8030-0EN

Issued 03-08


(The operational description for the overload relief valve is provided separately).

10)Anti-drift valve (Boom section) The anti-drift valve is installed on the boom bottom side of cylinder port A7 to prevent the natural drop of boom cylinder. 1] Neutral Status (Figure 11) The pressure on cylinder Port A7 passes the hollow cavity in poppet (1) via passage (A) and will be directed to the spring chamber (C) through passage (B). The force of the spring and the pressure acting on the area differences in the poppet (2) areas work to firmly seat poppets (1, 2). 2] Up (Figure 12) The oil supplied from the pump pushes open poppet (1) and flows out from cylinder Port A7. 3] Down (Figure 13) Switching poppet (1) by adding pressure to Port Pc2 will direct the oil in spring chamber (C) to the drain Port dr2 by way of passage (B), the hollow cavities in poppet (1) and spool (3). This opens poppet (2) and the returning oil from cylinder Port A7 flows into the tank passage through the boom 1 spool. The function can also be added to the cylinder port on the arm rod side.


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Issued 03-08



Issued 03-08


Combined Operations 1) Additional operation with travel (Figure 14) Operating the frontal control (in any section other than Travel) during traveling straight forward/ backward or during a spin turn (simultaneous operation of travel right/left), or traveling straight forward/backward or spin-turning during the operation of the frontal control will switch over the travel straight valve (1) due to the oil from the hydraulic power source for signals, which entered from Port PP. Therefore, the oil supplied from Port P2 (shown by arrows) is shut off from the neutral passage (C) on the 4-way valve side and will flow into parallel passage (D) on the 4-way valve side. It will also flow into parallel passage (B) on the 5-way valve side by way of the neck of travel straight valve and passage (E). Thus, the actuator for the frontal control is operated by the oil supplied from Port P2. At this time, the oil supplied from Port P1 (shown by arrows) is shut off from parallel passage (B) on the 5-way valve side and flows into cylinder Ports (A1, B1) in Travel Right Section through neutral passage (A) on the 5-way valve side. It also flows into the neutral passage (C) on the 4way valve side past passage (F) and the neck of travel straight valve, then flows into cylinder Ports (A6, B6) in the Travel Left Section through the hollow cavity in sleeve. Thus, travel is operated by the oil supplied from Port P1 and straight travel is maintained. Part of the oil supplied from Port P2 passes annular restriction (G), pushes up poppet (3) to be supplied to the travel controls. This helps eliminate the decelerating shocks at the time of travel straight valve (1) switch-over.


Issued 03-08


Relief Valve 1) Main relief valve 1] Operation of main relief valve

1- The relief valve is incorporated between the neutral passage “HP” and the tank passage “LP”. The oil will flow through the throttle of main poppet (1) to fill in the internal cavity (C). Also, the sleeve (2) and the main poppet (1) act on different areas “A, B” to ensure secure seating.

2- When the pressure on neutral passage “HP” reaches the programmed pilot spring force, the pilot poppet (3) opens. The oil flows around the peripheral of pilot poppet (3) and is directed into tank passage “LP” by way of drilled hole (D) and annular space (E).

3- As the pilot poppet (3) opens, the pressure in the internal space (C) decreases. As the main poppet (1) opens, the oil in “HP” flows directly into passage “LP”.


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2) Overload relief valve 1] Relief valve operation

1- The relief valve is incorporated between the cylinder Port “HP” and the low-pressure passage “LP”. The oil passes the hole on piston (C) and fills the internal space (G). It then acts on different areas and to make sleeve (K) and main poppet (D) securely seated.

2- When the pressure on neutral passage “HP” reaches the programmed pilot poppet spring force, the pilot poppet (E) opens. The oil flows around the peripheral of poppet and is directed into the low pressure side “LP” through the drilled hole (H).

3- As poppet (E) opens, the flow of oil passing the throttle (I) in piston (C) is generated, and a difference in pressure grows between the passage “HP” and the back side of piston (C). The piston (C) then moves and becomes securely seated with the poppet (E).

4- The oil flow from passage “HP” to the back side of poppet (D) will be restricted to the area (F) only, which is the annular space between poppet (D) and piston (C) and the throttle. As a result, the difference in pressure grows larger. Consequently, the poppet (D) opens and the oil flows directly into passage “LP”.


Issued 03-08


5- Intake An anti-void unit is installed to supply oil when cavitation takes place in cylinder Port “HP”. When the pressure on cylinder port “HP” is lower than the pressure on the low pressure side “LP”, the sleeve (K) opens due to the area difference between and . The oil enters the cylinder Port “HP” from the low pressure side “LP” to prevent cavitation.


Issued 03-08


SWING UNIT Functional and Operational Description 1) Swash Plate Motor Refer to Structural Drawing Figure 1. The cylinder block has 9 pistons installed. Also, the end of the cylinder block contacts the valve plates, which have two crescent-shaped ports A and B. Principle of torque generation When high pressure oil (Pressure P) is introduced into Port B, the oil pushes the swash plate by force per one piston (F = P x Ap, where Ap is the sectional area of a piston). The piston receives the reaction corresponding to the force from the swash plate. As a result, a component is generated in the rotational direction of the reaction. Then, rotational force is generated on the cylinder block by the collection of forces in the rotational direction of the piston on the high pressure side. The torque then is transferred to the shaft via spline for rotation. On the other hand, when the high pressure oil is introduced to Port A, the rotational direction will be reverse to the case described above. The output torque and the number of revolutions are calculated according to the following equations:


Issued 03-08

Copyright © 8030-24 Figure 1. Structural Drawing of Motor


Issued 03-08


2) Parking Brake (for models equipped with parking brakes) The parking brake is a hydraulic release type, wet multiple disc structure, having a shaft lock mechanism where brake ON/OFF is switched by external signal pressure. 1] When parking brake is ON See Figure 2-1: Structural drawing. When the hydraulic oil for brake release is shut off, the disc is connected to the peripheral of the cylinder block via splines. The brake piston (secured to prevent its rotation) is pushed by the force of spring, and the cylinder block and the case are secured by the force of friction. The shaft, therefore, will be locked. 2] When parking brake is OFF See Figure 2-2: Structural drawing. When the hydraulic oil for brake release is introduced to the brake cylinder chamber (C) through Port PB (Port PG for models with parking brake), the brake piston starts moving due to release pressure against the force of spring. The shaft then will be free to rotate since there is no friction.


Issued 03-08


3) Principle of Relief Valve Operation The relief valve determines the driving force and the braking force at the time of hydraulic shovel swing. They are installed on lines A and B of the main port. It also has a circuit which forces the returning oil from relief valve to go back to the opposing main low pressure line via makeup valve. Also, it is designed to reduce shocks at start of acceleration / deceleration. The relief valve structure has two components: 1] Area difference direct acting relief valve 2] Shockless piston as shown in Figure 3-1. Shockless type relief valves help eliminate shocks and stresses generated on intensified components. • Pressure Setting of Relief Valve versus Adjustment Volume of Relief Valve (for reference) Per one time: Approximate 9.7 MPa {1406 psi} Do not attempt to make adjustments as long as there are no problems.


Issued 03-08


The relief valve operates in two steps as follows: • Initial stage (see Figure 3-2) At the beginning of the operation, the shockless pin moves to maintain low pressure in the spring chamber. Thus, the area for receiving pressure on poppet will be the area of poppet seat (S1). This is considerably large compared to the area for receiving pressure at the normal relief setting (S1-S2). The relief operating pressure, therefore, will be held low until the shockless spin has completely moved. The duration for which the pressure is held low will be determined according to the orifice diameter between poppet and piston, the area of free piston for receiving pressure, and the free piston stroke.


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• Second stage (see Figure 3-3) By the time the shockless piston has moved completely, the pressure in the spring chamber has risen, and the front and the back pressures of the poppet have become equal. The relief valve, therefore, operates on the pressure setting for normal operation.

Figure 4 compares the pressure waveforms between the conventional type and the shockless type.


Issued 03-08


4) Makeup Valve The makeup valve functions in two ways as described below: First it keeps the swing body from overrunning by preventing cavitation, which is caused by swing body overrun. If the motor had pumped due to inertia of the swing body and the motor revolutions have exceeded the adequate number of revolutions suitable for the oil inflow to motor, the shortage of oil will be supplemented into the main motor circuit via the makeup valve. Thus, the generation of vacuum in the circuit will be prevented. Secondly, it maintains the normal circuit conditions for braking by preventing the generation of vacuum in the circuit. The situation applies at the time of braking, for example, when a closed circuit was formed between the control valve and the motor. The makeup valve supplements the amount of the motor drainage and the valve leakage to prevent the circuit from being vacuumized.


Issued 03-08


5) Reduction Gear (2-stage planetary gear) See the sectional drawing below. The motor shaft (1) is spline-jointed to the drive gear (2). The driving force from the hydraulic motor is transferred to the planetary gear (3), which engages with the drive gear (2). The planetary gear (3) engages with the ring gear in the reduction gear housing (4). The planetary gear thus revolves along the gear ring while it rotates. The planetary gear (3) is held by the holder (5) via a bearing. The holder transfers the orbital motion of the planetary gear (3) to the sun gear (6), which is spline jointed to the holder. The sun gear (6) engages with the planetary gear (7) and transfers orbital motion to the planetary gear (7) in the same manner as in the first step. The planetary gear (7) revolves as it rotates because it engages with the ring gear in housing (4). Since the planetary gear (7) is held by holder (8) via a bearing, the holder (8) transfers the orbital motion of the planetary gear (7) to the pinion shaft (9), which is spline jointed to the holder.


Issued 03-08


Overview 1) Features 1- The valve enhances operability by reducing the number of reverse rotations when the swing body stops. 2- As the valve has few components and is structurally simple, maintaining the valve is easy.

2) Operational Description The anti-reverse valve prevents reverse rotational motion caused by entrapped pressure at the time the swing body is stopped. This is achieved by directly connecting the motor’s main line to the makeup line for a certain period of time when the motor stops. The anti-reverse valve consists of the following parts as shown in Figure 1. 1- Check valve 2- Flow control valve (integrated in check valve) 3- Sleeve (Combined with check valve to form a high pressure selection valve). 4- Orifice A 5- Orifice B


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Issued 03-08


When control valve is in neutral (Ports P1, P2 on the motor at the same pressure). The check valve will be balanced at the center with the spring force.

When the swing body is activated, the check valve on high pressure side is pushed and the check valve will be seated.

At the time of applying the brake, the check valve is stroked by the brake pressure and will be seated.


Issued 03-08


After the motor has been stopped by the braking action of the valve unit, it will try to move in the reverse direction due to the entrapped pressure in the main line. This reverse pressure will seat the shuttle valve (sleeve) in check valve onto the check valve on low pressure side. An oil passage is thus formed between the port on which reverse pressure is applied (Port Pv2) and the port which is connected to the main makeup line (Port Cv). Through this oil passage, the reverse pressure will be released into Port Cv.

At the same time, the reverse pressure pushes the check valve in the direction opposite of the direction of braking. The flow control valve integrated into the check valve, which now is the low pressure side, releases oil in the damper chamber 1 at a fixed volume. The check valve, therefore, starts stroking at a speed.

In the end, the check valve becomes seated and the oil passage formed between Port Pv2 and Port Cv is blocked. Lep SC75SRCX80-8030-0EN

Issued 03-08


TRAVEL UNIT (CX75SR) External Dimensional Drawing


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Basic Structure and Drawings 1) Basic structure of GM motor

• Reduction gears The reduction gears are composed of a spur gearbox (referred to as “primary reduction gears”) and a differential gearbox (referred to as “secondary reduction gears”) in which pericycloid tooth profiles are adopted. The gears work to reduce the high-speed rotational motion from the hydraulic motor and to convert it into a low speed rotation with high torque. • Hydraulic motor The hydraulic motor is a swash plate type axial piston motor. The motor converts the force of pressurized oil delivered from the pump into a rotational movement. • Brake valve The brake valve consists of various types of valves. It stops the hydraulic motor smoothly, prevents the motor from overrunning, and also prevents extreme high pressure from being generated at the time the motor is stopped abruptly. • High/low 2-step switching mechanism The valve consists of a switching valve and a piston. It switches the piston displacement of the hydraulic motor in two different steps. • Parking brake The parking brake has a friction-plate type braking mechanism and is integrated into the hydraulic motor section.


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Issued 03-08


2) Parts list PART NAME

SYM

QTY

Hub

1

1

Spindle

2

Carrier

3

Sun gear(1)

PART NAME

SYM

QTY

Oil seal

132

1

1

O-ring

135

1

O-ring

139

4

1

Snap ring

145

1

Planetary gear(1)

5

3

Ball bearing

149

1

Sun gear(2)

6

1

Ball bearing

150

1

Planetary gear(2)

7

4

Roller

151

3

Thrust coller(1)

9

1

Piston

161

1

Thrust washer(1)

10

4

Shoe

162

1

Thrust washer(2)

11

4

Pivot

167

2

Thrust washer(3)

12

3

Parallel pin

171

2

Cover

13

1

Spring

190

1

Ring nut

22

1

Valve seat

201

2

Ball bearing

24

2

Valve

202

2


27

3

Sleeve

203

2


28

4

Coller

204

2

Inner ring

29

3

Plug

205

2

SYM

QTY

Plug

383

1

1

O-ring

392

1

1

Name plate

399

1

Inner ring

30

4

Spring

206

2

Floating seal

31

2

O-ring

207

2

Plug

33

1

Backup ring

208

4

O-ring

35

1

O-ring

211

2

O-ring

37

3

O-ring

212

2

Socket plug

39

2

Shim

213

2

Hex.head bolt

40

3

Piston

214

2

Steel ball

41

1

O-ring

215

2

Parallel pin

42

2

Backup ring

216

4

O-ring

43

2

Rear flange

301

1

O-ring

44

1

Plug

321

1

Ring

45

1

Spool

323

1

Hex.socket set screw

47

2

Plug

324

2

Retainning ring

50

1

Spring retainer

325

2

Hex.head bolt

51

4

Valve

327

2

Shaft

102

1

Spring

328

2

Swash plate

103

1

Spring

330

2

Cylinder block

104

1

O-ring

336

2

Piston

105

9

O-ring

338

3

Shoe

106

9

Pallalel pin

342

1

Retainning plate

107

1

Hex.socket bolt

345

8

Thrust ball

108

1

Hex.socket plug

352

5

Timing plate

109

1

Spool

363

1

Washer

110

2

Spring

366

1

Washer

111

1

Steel ball

368

1

Piston

112

1

Hex.socket plug

375

4

Spring

113

10

Orifice

377

2

Spring

114

1

Filter

379

1

Friction plate

115

2

Orifice

380

1

Mating plate

116

3

Plug

382

3


PART NAME

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Operational Description 1) Reduction gears 1] Functions

The reduction gears are composed of a spur gearbox (referred to as “primary reduction gears”) and a differential gearbox (referred to as “secondary reduction gears”) in which pericycloid tooth profiles are adopted. The gears work to reduce the high-speed rotational motion from the hydraulic motor and to convert it into a low speed rotation with a high torque. 2] Operational description 1- Primary reduction gears section 1)The rotational movement of the hydraulic motor is output from shaft (102). The rotation is transferred onto the input gear (6) which is spline jointed with the shaft G (15). The input gear (6) is engaged with three spur gears (7). The spur gears (7) are reduced to lower speed and will rotate in the reverse direction. The reduction gears section with input gear (6) and spur gears (7) is called the primary reduction gears section. The reduction ratio (i1) of this section is as follows:


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2- Secondary reduction gears section 1)Each of the three spur gears (7) is connected to the crankshaft (9). When the spur gear (7) rotates, the crankshaft (9) rotates in the same direction and for the same number revolutions. This rotational movement causes the eccentric body sections A and B of the crankshaft (9) to start their eccentric movement (orbital motion). This eccentric movement (orbital motion) is transferred to the RV gears A (4) and B (5) via the needle roller bearing (23). In this manner, the RV gears A (4) and B (5) engage in eccentric movement in the same direction and for the same number of revolutions as the spur gears and crankshaft.


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2) The faces of teeth on RV gear A (4) and RV gear B (5) are always engaged with the pins (17) (number of pins: Zp). When the RV gear A and the RV gear B start their eccentric movements, the mesh point shifts on the faces of teeth sequentially while rolling. During one turn of eccentric movement, the pin (17) rotates together with the hub (1) for the difference value (Zp – Zr), which is equal to the difference between Zr (the total gear teeth number of RV gears A and B) and Zp (the number of pins). The rotational direction of hub (1) is the same as the direction of eccentric movement on RV gear. The rotation of hub (1) is the output rotation. The secondary reduction gears section is where the reduction takes place through crankshaft, RV gear, pin and hub. The reduction ratio (i2) in the secondary reduction gears section is as follows:

3) The entire reduction gear The reduction gears will operate at the product ratio of the primary reduction gears section and the secondary reduction gears section. Therefore, the number of output revolutions (reduction ratio i) for the reduction gears after the hydraulic motor shaft has made one complete turn will be as follows:


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2) Hydraulic drive section This section describes the hydraulic motor, brake valve, parking brake, which are driven by hydraulic oil, and the high/low 2-step switching mechanism of the hydraulic motor. 1] Functions 1- Hydraulic motor The hydraulic motor is a swash plate type axial piston motor. The motor converts the force of pressurized oil delivered from the pump into a rotational movement. 2- Brake valve 1) The valve controls the inertial force at the time the hydraulic motor is stopped to enable a smooth stopping of the motor. 2) The valve also keeps the hydraulic motor from overrunning when an external force causes the motor to rotate. This, in other words, will prevent hydraulic oil cavitation. 3) It also prevents the generation of extreme high pressure when the hydraulic motor is stopped abruptly. 3- High/low 2-step switching mechanism This switches the hydraulic motor in two steps: the high-speed rotation with a low-torque output and the low-speed rotation with a high-torque output. 4- Parking brake The parking brake works when the hydraulic motor is being stopped and prevents the motor from rotating due to an external force. It has a friction-plate type braking mechanism and is integrated into the hydraulic motor section.


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Copyright © 8030-43 2] Principle and operational description

1- Hydraulic Motor The pressurized oil supplied from the hydraulic pump enters the rear flange (201) in the GM motor. The pressurized oil is directed into the cylinder block (104) through the brake valve and the timing plate (109). The oil will be directed into one side only of the area divided by the Y1-Y2 line drawn from the top to the bottom dead centers of the piston (105) stroke. The pressurized oil pushes each of the pistons (105) and generates a force F (= P x A). The force will act on the inclined surface of the swash plate (103). Due to the angle° of this inclined surface, the force F will be divided into component forces F2 and F3. Of these component forces, the radial component force F3 generates a torque (= F3 x ri). The resultant force T (= Σ [F3 x ri]) of each piston (105) is the rotational force for the hydraulic motor. The rotational force will rotate the cylinder block (104) and the shaft (102) via piston (105).


Issued 03-08


2- Brake valve The ports A and B are the inlet/outlet for the hydraulic oil. The following describes the case in which the hydraulic oil (pressurized oil) is supplied to Port A. The flow and the operation will be reversed when the oil is supplied to Port B. The rotational direction of the motor will also be reversed in this case. 1) During normal operation The hydraulic motor will start rotating when the pressurized oil is supplied to Port A from the pump. The details will be described as follows. The pressurized oil supplied from the pump first enters Port A and opens the valve (227). The pressurized oil which has passed the valve (227) and entered the hydraulic motor via Port C will give the rotational force to the hydraulic motor. Pressurized oil also enters Port A, passes the passage (a) through a small hole in spool (223) and enters the chamber (b). The spool (223) slides from the neutral position to the left by the force of the pressurized oil in chamber (b). At this time, a hydraulic oil passage is formed between the Ports D and B due to the grooves in the spool. The hydraulic oil discharged from the hydraulic motor flows in Port B from Port D. In this manner, the hydraulic motor rotates and the hydraulic oil returns to the oil tank. On the other hand, the pressurized oil enters Port E when the spool (223) slides to the left, and the oil in Port E flows into the parking brake and the 2-step switching valve.


Issued 03-08


2) Stopping (by applying the brake) The hydraulic motor will stop rotating when the supply of pressurized oil is stopped. The details will be described as follows. When the supply of pressurized oil to Port A is discontinued, the pressure in Port A and chamber b decreases. As the pressure decreases, the spool (223) starts moving towards the right from the left position to the neutral position by the force of spring (228). In conjunction with the movement of spool (223), the passage area between the Ports D and B becomes smaller. When the spool reaches the neutral, the passage will be shut off. The hydraulic motor, on the other hand, keeps rotating due to inertial force even after the supply of pressurized oil stopped. The hydraulic oil discharged from the hydraulic motor thus loses its passage to flow out from Port D. In this manner, the hydraulic oil on Port D increases its pressure. The hydraulic oil with the boosted pressure passes the throttle of a valve (287) on the right-hand side and enters chamber (g) through chamber (f). Because of the hydraulic oil entering chamber (g), the piston (286) on the right-hand side will shift to the left portion to keep the pressure from rising. During the movement, the pressures in the chambers (r) and (g) stay lower than the pressure in Port D through the effect of the orifice in valve (287). At the same time, the valve (287) on the right-hand side stays open due to the difference in pressures. The hydraulic oil flows into Port C from Port D. When the piston (286) reaches the end of its stroke, the pressures in the chambers (g) and (f) rise and become equal to the pressure in Port D. The valve (287) on the right-hand side then closes again. As the oil discharged from Port D loses its next flow passage, the pressure continues to rise. The valve (287) on the left-hand side then opens and the hydraulic oil in Port D flows into Port C. In time, the pressure in Port D decreases along with the decrease in inertial force, and valve (287) on the left side closes again. The hydraulic motor will also stop its rotation. In this manner, the hydraulic motor will be stopped smoothly by the brake through controlling the pressure in Port D in two separate steps.


Issued 03-08


3) Anti-overrun features When the hydraulic motor is forced to rotate by external forces during its normal operation, an overrunning will occur. This occurs, for instance, when an excavator is traveling down a steep slope at the same time as working the travel motor for a power shovel. The mechanism against the overrun phenomenon is described below. The hydraulic motor, during its normal operation, is forced to rotate by an external force. The pressure of the hydraulic oil (supplied to Port A or Port B) decreases. The spool (223) starts moving toward the center as the pressure reaches the level that causes the motor to overrun. In conjunction with the movement of spool (223), the area of the passage between Port D, which is at the outlet side of the hydraulic motor, and Port B becomes smaller. The hydraulic oil flow discharged into Port B from Port D also becomes limited. At the same time, the pressure on Port D (back pressure) also increases. The overrunning will be prevented in this manner by controlling the oil flow/pressure at the outlet port of the hydraulic motor.


Issued 03-08


3- High/low speed 2-step changing mechanism (during 2-speed manual switch) 1) Low-speed At low speed, the pilot pressure is not supplied from Port P. At this time, the spool (271) is pushed to the left by the force of spring (281) and the pressurized oil in Port F is being shut off. The hydraulic oil in chamber S is released into the drain (motor case) via spool (271). The thrust of the piston (161) is small at this stage. The swash plate (103) is positioned along the surface Y. The swash plate (103), then, reaches its maximum incline angle of 1°. In other words, the hydraulic motor reaches its maximum piston displacement and rotates at low speeds.


Issued 03-08


2) High speed At high speed, 3.92 MPa {568 psi} of pilot pressure is supplied from Port P. At this time, the spool (271) is pushed to the right, overcoming the force of spring (281). The pressurized oil in Port F is introduced into chamber S via spool (271). The thrust of the piston (161) becomes stronger because of the pressurized oil in chamber S. The piston (161) pushes the swash plate (103) until it hits the surface X, then holds the plate there. The swash plate (103) is at its minimum incline angle of 2°. In other words, the hydraulic motor is at its minimum piston displacement and rotates at high speeds.


Issued 03-08


4- Parking brake 1) During operation The pressurized oil is supplied from the pump to Port A or Port B. The spool (223) in the brake valve then moves towards the left or right. By the time the spool has moved all the way, the Port E opens. The pressurized oil is thus introduced into the cylinder chamber (c) from Port E. When the oil pressure reaches 0.47 MPa {68 psi} or above, the thrust of piston (112) becomes larger than the force of spring (113). The piston (112) moves toward the rear flange (201). The force that has been pushing the counterpart plate (116) and the friction plate (115) from the piston, therefore, ceases to exist, allowing the friction plate (115) to rotate freely here. Because the friction plate (115) engages with the cylinder block (104) in the hydraulic motor section, the braking force on the cylinder block (104) will also be released, and the hydraulic motor will also be free to rotate.


Issued 03-08


5- When applying the brake to stop The supply of pressurized oil to Port A or Port B is stopped. The spool (223) in the brake valve then moves to the neutral position. Port E shuts off. The pressure in the cylinder chamber (c) decreases. When the pressure drops to 0.47 MPa {68 psi} or below, the hydraulic force of piston (112) becomes smaller than the force of spring (113). The piston pushes the counterpart plate (116) and the friction plate (115) with the force of the spring (113). This pressing force generates a friction force, which will be used for braking. The friction plate (115) engages with the cylinder block (104) in the hydraulic motor section. The cylinder block (104) engages with the shaft (102) of the hydraulic motor section. In this manner, the braking torque will be applied to the hydraulic motor at the time the machine is stopped.


Issued 03-08


TRAVEL UNIT (CX80) External Dimensional Drawing


Issued 03-08


Basic Structure and Drawings 1) Basic structure of GM motor 1st stage Reduction 2nd stage Reduction High-Low 2-Speed Switching Mechanism

Parking Brake

Brake Valve

Hydraulic Motor

Reduction Gear


AO13001 016

Issued 03-08

Copyright ©

AO13001-017

8030-53


Issued 03-08


2) Parts list PART NAME Hub

SYM

QTY

1

1

PART NAME Mating plate

SYM

QTY

116

3

PART NAME Plug

SYM

QTY

383

1

Spindle

2

1

Oil seal

132

1

O-ring

392

1

Carrier

3

1

O-ring

135

1

Name plate

399

1

Sun gear(1)

4

1

O-ring

139

1

Planetary gear(1)

5

3

Snap ring

145

1

Sun gear(2)

6

1

Ball bearing

149

1

Planetary gear(2)

7

4

Ball bearing

150

3

Thrust coller(1)

9

1

Roller

151

1

Thrust washer(1)

10

4

Piston

161

1

Thrust washer(2)

11

4

Shoe

162

2

Thrust washer(3)

12

3

Pivot

167

2

Cover

13

1

Parallel pin

171

1

Ring nut

22

1

Spring

190

2

Ball bearing

24

2

Valve seat

201

2


27

3

Valve

202

2


28

4

Sleeve

203

2

Inner ring

29

3

Coller

204

2

Inner ring

30

4

Plug

205

2

Floating seal

31

2

Spring

206

2

Plug

33

1

O-ring

207

2

O-ring

35

1

Backup ring

208

4

O-ring

37

3

O-ring

211

2

Plug

39

2

O-ring

212

2

Hex.head bolt

40

3

Shim

213

2

Steel ball

41

1

Piston

214

2

Parallel pin

42

2

O-ring

215

2

O-ring

43

2

Backup ring

216

4

O-ring

44

1

Rear flange

301

1

Ring

45

1

Plug

321

1

Hex.socket set screw

47

2

Spool

323

1

Retainning ring

50

1

Plug

324

2

Hex.head bolt

51

4

Spring retainer

325

2

Washer

52

1

Valve

327

2

Shaft

102

1

Spring

328

2

Swash plate

103

1

Spring

330

2

Cylinder block

104

1

O-ring

336

2

Piston

105

9

O-ring

338

3

Shoe

106

9

Pallalel pin

342

1

Retainning plate

107

1

Hex.socket bolt

345

8

Thrust ball

108

1

Hex.socket plug

352

3

Timing plate

109

1

Spool

363

1

Washer

110

2

Spring

366

1

Washer

111

1

Steel ball

368

1

Piston

112

1

Hex.socket plug

375

4

Spring

113

10

Filter

379

1

Spring

114

1

Orifice

380

1

Friction plate

115

2

Plug

382

3


Issued 03-08


Operational Description 1) Reduction gears 1] Functions

This reduction gear unit is composed of two stage planetary gear mechanism. The reduction gear reduces the high seed of hydraulic motor and converts it low-speed, hightorque rotation. 2] Operational description The rotation of hydraulic motor shaft is transmitted to sun gear [4] of the first stage which is linked with shaft [102] in spline. Sun gear [4] is meshed with three planetary gears [5], and three planetary gears [5] mesh with hub [1] while rotating on their axis. At that time, the hub is rotated by the rotation of the planetary gears [5]. The hub rotation is transmitted to carrier [3] which connected to planetary gears [5], and that causes sun gear [6] rotation of the second stage. The rotation of sun gear [6] is transmitted to the hub via four planetary gears [7] of the second stage. The generated rotation of reduction gear is output rotation.

Hub [1]

Planetary gear [7] Planetary gear [5]

Spindle [2]

Shaft [102]

In put

Out put

Sun gear [6]

Sun gear [4] Carrier [3] AO13001-018


Issued 03-08


2) Hydraulic drive section This section describes the hydraulic motor, brake valve, parking brake, and high-low 2-speed switching mechanism of the hydraulic motor. 1] Functions 1- Hydraulic motor Hydraulic motor is referred to as a swash plate type axial piston motor which converts the pressure oil power fed by pump into rotary motion. 2- Brake valve 1) Travel motor controls the force of rotational inertia of the body to brake and stop the rotation smoothly. 2) Check valve function to prevent hydraulic motor from cavitation. 3) Open the port to release the parking brake force at travel motor operation, and close the port at a standstill. 3- Relief valve 1) Softens the shock when starting the hydraulic motor, softens the shock when stopping the hydraulic motor, and prevents cavitation through the relief operation (reduction of the stop brake sound). 2) When sudden pressure operates on the hydraulic motor, the relief valve keeps the pressure to a predetermined level or less to prevent damage to the hydraulic motor. 4- High-low 2-speed switching mechanism Switches the hydraulic motor between high speed rotation with low torque, and low speed rotation with high torque. 5- Parking brake The parking brake is used the prevent machine from running away or slipping while parking on a slope using the friction plate type brake mechanism, and it installed on the hydraulic motor.


Issued 03-08

Copyright © 8030-57 2] Principle and operational description

1- Hydraulic Motor Hydraulic fluid fed by pump enters rear flange [301] of travel motor, and is led from timing plate [109] to cylinder block [104] through brake valve mechanism. This pressure oil is led to only the one side of (Y1)-(Y2) tied between top dead point and bottom dead point of piston [105] stroke. And the pressure led to one side of cylinder block pushes 4 or 5 pistons [105], generating the power (F1 kgf = P kgf/cm2 x A cm2). This power enters on swash plate [103], but swash plate is fixed having an angle (x) against axis of drive shaft [102], and divided into component of force (F2, F3). And the radial component of force (F3) generated various torque (T= F3 x ri) against line. The total torque T [= Σ (F3 x ri)] is connected turning effort, and rotates cylinder block [104] through piston [105]. The cylinder block [104] is connected with drive shaft [102] with spline, and rotates drive shaft [102] to transmit torque. 301

104

105

109

102

103

P

P

Y1

F3

A

F2

F3

ri

F1 F3

F3 F3

x Y2

AO13001-019


Issued 03-08


2- Brake valve Port (A) and Port (B) are the input and output ports for the working fluid. The following description assumes that the working fluid (hydraulic) is fed through port (A). If the fluid is fed through port (B), the flow and motion are reversed. The direction of Rotation of the motor is also reversed. 1) During normal operation Hydraulic fluid is fed from the pump to port (A), causing the hydraulic motor to rotate. The details are as follows. First, the hydraulic fluid fed from the pump enters at port (A) and opens the valve [327]. The fluid oases through the valve [327], enters the hydraulic motor through port (C) and applies rotary force to the hydraulic motor. At the same time, hydraulic fluid enters at port (A) and passes through small holes in the spool [323] and through channel (a) to chamber (b). The hydraulic pressure in chamber (b) causes the spool [323] to move from the central position to the left. At this time a groove in the spool [323] forms a channel for hydraulic fluid to pass between port (D) and port (B). Hydraulic fluid ejected from the hydraulic motor flows from port (D) to port (B), and the hydraulic motor rotates. The hydraulic fluid returns to the oil tank. Also, as the spool [323] oscillates to the left, hydraulic fluid enters port (E). The hydraulic fluid at port (E) flows to the parking brake and 2-speed switching valve.

Parking brake E 323

323

a

b

327

D

B

A

D

C

C

328 B

A AO13001-020


Issued 03-08


2) Stopping (by applying the brake) If pressurized oil supply through the port (A) is suspended while traveling, the hydraulic force to push up the spool is lost, and the spool [323] which is slid to left side, tries to return to the neutral position through the spring retainer [325] due to the spring [328] force. At that time, through the oil in the chamber (b) tries to flow out to the port (A) side through the passage (a) in the spool [323], its flow is restricted and some back pressure is generated by the throttle effect in the passage (a) controlling the return speed of the spool [323]. At the same time, the hydraulic motor tries to rotate with its inertia force even though the pressurized oil is suspended, and the return oil from the hydraulic motor tries to return to the port (B) side from the port (D) through the passages on spool groove and rear flange. When the spool [323] entirely return to neutral position, the passage on the hydraulic motor of the oil return side is completely closed by the spool [323], and the hydraulic motor ceases its rotation. While machine working, the brake valve smoothly stops rotation of the hydraulic motor which tries to rotate with its inertia force, by means of throttling the return side passage of the hydraulic motor, generating back pressure due to shape of the spool groove and controlling the return speed of the spool [323]. On the other hand, when braking is operated, the hydraulic motor tries to rotate with its inertia force and to intake oil with its pumping function. However, because the intake side is closed its passage with the spool [323], the oil supply is suspended. This causes cavitation in the hydraulic motor. To prevent the cavitation, the valve [327] is operated by very slight negative pressure to open the passages of port (A) side and intake port (C) of the hydraulic motor. And when pressurized oil is supplied through the port (B), each motion of the mentioned parts above becomes symmetrical right and left to stop the hydraulic motor.

Parking brake 301

323 a

325 323

b

327

D

B

C

D

A

C

328 B


A

AO13001-021

Issued 03-08


3) Anti-racing function During normal operation, when a hydraulic motor is rotated by an outside force, a condition called racing runaway can occur. For example when used as the drive motor for a excavator, racing can occur when the vehicle moves down a steep slope. This section describes the mechanism used to prevent this condition. During normal operation, the hydraulic motor is rotated by an outside force. The pressure of the hydraulic fluid feed (at port (A) or port (B)) falls. As the pressure approaches the level at which racing begins, the spool [323] begins moving to the center towards the central position. The movement of the spool [323] reduces the size of the flow channel from port (D) to port (B) on the output side of the hydraulic motor. This restricts the amount of hydraulic fluid ejected from port (D) to port (B). At the same time the pressure at port (D) (back pressure) increases. Thus racing is prevented by controlling the flow rate and pressure at the escape port from the hydraulic motor.

Parking brake 301

323 a

323

b

327

D

B

A

D

C

C

328 B


A

AO13001-022

Issued 03-08


3- Operation description of relief valve 1) Starting The pressurized oil supplied from the pump is led to port (C) from port (A). Port (C) is connected with the hydraulic pressure motor. Therefore, the hydraulic motor can give torque with the pressurized oil led to port (C). At this time, the valve [202-a] of the relief valve(R/V) «A» is not opened for the pressurized oil of port (C). The piston [214-a] moves to the stroke end of the direction of an arrow with the pressurized oil. The oil of chamber (x) is led to port (D) through the orifice (c) of the sleeve [203-a], the orifice (b) of the valve [202-a]. The pressurized oil of port (C) opens the valve [202-b] (b) of the relief valve «B» with set pressure, and pressurized oil is led to port (D). The pressurized oil from port (C) is led to the chamber (y) through the orifice (f) of the valve [202-b], the orifice (g) of the sleeve [203-b]. If the piston [214-b] reaches the stroke end, the pressure between the orifice (f) of the valve [202-b] and the orifice (g) of the sleeve [203-b] will rise. The cracking pressure of the valve [202-b] turns into more than the system pressure of the excavator with the pressure during two orifices, and the valve [202-b] is closed. The pressure of port (C) rises by the operation of the relief valve (R/V) «A» and «B», and the hydraulic motor can obtain torque.

chamber(y) a

214 orifice(f) 202

b 203

a

orifice(c) R/V "B" D C R/V "A" 203

b

orifice(g) chamber(x)

214

b

202 B

A

a

orifice(b) AO13001-023


Issued 03-08


Pressure

The pressure of the port (C) at starting is as follows.

Time

Relief valve "B" is opened AO13001-024

Pressure

However, when the piston [214-b] position has reached the stroke end in the case of the last stop, the valve [202-b] of the relief valve (R/V) «B» is not opened. The pressure of the port (C) in this case is as follows.

Time AO13001-025

The pressure of the port (C) at starting changes with the piston [214-b] positions. NOTE: When the pressurized oil supplied from the pump is led to port (D) from port (B), operation explanation

becomes what replaced the relief valve (R/V) «A» and relief valve (R/V) «B».


Issued 03-08


2) Stopping If supply of pressurized oil in Port (A) is lost, the counter balance valve will return to neutrality. Port (D) will be intercepted if the counter balance valve returns to neutrality. However, since the hydraulic motor rotates according to inertia, the pressure is generated in port (D). The pressurized oil of port (D) is led to the chamber (x) through the orifice (b) of the valve [202-a], the orifice (c) of the sleeve [203-a]. The piston [214-a] moves to the stroke end of the direction of an arrow with the pressurized oil led to the chamber (x). While the piston [214-a] is moving, the pressure in the chamber (x) does not rise. The pressurized oil of port (D) opens the valve [202-a] of the relief valve (R/V) «A» with set pressure, and pressurized oil flows into port (C). (Pressure under piston movement : Primary relief pressure) The pressure of port (D) is controlled by the operation of the relief valve (R/V) «A», and the cavitation is prevented by supplying oil to port (C). If the piston [214-a] reaches the stroke end, the pressure of chamber (x) and the pressure between the orifice (b) of the valve [202-a] and the orifice (c) of the sleeve [203-a] will rise, and the valve [202-a] is closed. At this time, the relief valve (R/V) «A» is relieved above the system pressure of the excavator, and stops the hydraulic motor. (Pressure at the time of the completion of a piston move : Secondary relief pressure) The piston [214-b] of the relief valve (R/V) «B» moves to the direction of an arrow with the pressurized oil of port (D). The oil of chamber (y) is led to port (C) through the orifice (g) of the sleeve [203-b], the orifice (f) of the valve [202-b].

chamber(y) 214

a

orifice(f) 202 b 203 a orifice(c) R/V "B" D

C R/V "A"

203

b

orifice(g)

chamber(x) B 214

b

A

202

a

orifice(b) AO13001-026


Issued 03-08


Pressure

The pressure of the port (D) at stopping is as follows.

Time

Piston [214-a] is moving

Relief valve "A" is opened. AO13001-027

Pressure under piston movement : Primary relief pressure Pressure at the time of the completion of a piston move : Secondary relief pressure


Issued 03-08


4- High-low 2-speed switching mechanism 1) Low-speed When the pilot pressure is shut off from port (P), the GM motor is low speed level. At this time the spool [363] is pressed the left side by the force of the spring [366], the pressurized oil supply at port (F) is shut off. The oil in chamber (S) is released into the motor case through the spool [363]. The force of the piston [161] is small. The swash plate [103] is parallel to side (Y). At this time the swash plate [103] is tilted at a maximum angle (1). thus leading to lowspeed operation.

363

161

P

chamber S drain

1

F 366 fulcrum A or

side Y

B

103

B

A AO13001-028


Issued 03-08


2) High speed When the pilot pressure supplied to port (P), the GM motor is high speed level. At this time the pressure overcomes the force of the spring [366] and the spool [363] is pressed the right side. The pressurized oil supply from port (F) is then introduced into chamber (S) through the spool [363] . The force of the piston [161] is increased by the pressurized oil of chamber (S). The piston [161] pushes the swashl plate [103] up until it touches side (X) and keeps it. At this time the swash plate [103] is tilted at a minimum angle (2), thus leading io high-speed operation.

161

363

chamber S

P

2

366

F fulcrum

A

or

B

side X

103

B

A AO13001-029


Issued 03-08


3) Automatic switching from high speed to low speed As the load on the hydraulic motor increases, the pressure at port (A) or (B) Increases. While operating at the high speed level, when the pressure at port (A) or (B) reaches setting pressure, the spool [363] is pressed leftwards. From this point, the operation is as described for ' Low Speed Level '. The force of piston [161] is reduced, and the hydraulic fluid of chamber (S) is opened to drain (motor case) through the spool [363]. The swash plate [103] is positioned along side (Y). At this time the swash plate [103] has its maximum angle (1). Thus in this state the hydraulic motor has maximum displacement with low rotary speed.

363

161

P

chamber S

drain

1

F 366 fulcrum A

or

side Y

B

103

B

A AO13001-030


Issued 03-08


5- Parking brake 1) Travering Hydraulic fluid is fed from the pump to port (A) or port (B), causing the brake valve spool [323] to move to the left or right. The movement of the spool [323] opens port (E). The hydraulic oil is fed from port (E) to cylinder chamber (c). When the hydraulic pressure reaches 0.63 MPa (6.42 kgf/cm2), the force of the piston [112] exceeds the force of the spring [113]. The piston [112] moves in the direction of the rear flange [301]. The pressure from the piston [112] on the mating plates [116] and the friction plates [115] disappears, and the friction plates [115] is able to rotate freely. The friction plate [115] is locked to the cylinder block [104] of the hydraulic motor. Thus the braking force of the cylinder block [104] is released, and the hydraulic motor is able to rotate freely.

104

112

116

115

Parking brake E 323

a

b

301 328 113

C

B

A AO13001-031


Issued 03-08


2) Stopping The supply of hydraulic fluid to port (A) or (B) is Stopped. The brake valve spool [323] moves to the center position, shutting off port (E). The pressure in cylinder chamber (c) falls. When this pressure falls below 0.63 MPa (6.42 kgf/cm2), the hydraulic force of the piston [112] becomes less than the force of the spring [113]. The spring [113] causes the piston [112] to press against the mating plates [116] and friction plates [115]. This pressure creates the friction that serves as the braking force. The friction plate [115] is locked to the cylinder block [104] of the hydraulic motor. The cylinder block [104] is Iocked with the shaft [102] of the hydraulic motor. Thus brake torque is applied to the hydraulic motor while stopped.

104

112

116

115

102

301 113


C

AO13001-032

Issued 03-08


NOTES .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... ....................................................................................................................................................................................


Issued 03-08

Copyright ©

Section 9007

9007

AIR CONDITIONING UNIT

CNH

Lep SM75SR9007-0EN


Copyright © 9007-2

TABLE OF CONTENTS AIR CONDITIONER ................................................................................................................................................. 3 DISASSEMBLING THE CASE .................................................................................................................................... 3 Removing the switch box: ................................................................................................................................. 3 Removing the upper case: ................................................................................................................................ 3 REPLACING THE BLOWER MOTOR........................................................................................................................... 4 REPLACING THE EVAPORATOR ............................................................................................................................... 4 REPLACING THE EXPANSION VALVE........................................................................................................................ 5 REPLACING THE HEATER CORE .............................................................................................................................. 6 REPLACING THE MOTOR ACTUATOR ....................................................................................................................... 6

Lep SM75SR9007-0EN

Issued 08-2008

Copyright © 9007-3

AIR CONDITIONER 1 Disassembling the case

Switch box Top of case

Filter A Heater core Evaporator To remove clamps

Retainers

Retainers

Filter C

Clamp Blower motor

Filter B Figure 2 Figure 1

MQ18001-001

1 Removing the switch box: 1.

Remove 6 screws (M4 x 10) and pull out the switch box.

2 Removing the upper case: 1.

Remove filter A.

2.

Remove filters B and C.

3.

Remove 3 screws (M5 x 12).

4.

Remove 11 clamps using a flathead screw driver.

MSM-17-18-001

Issued 08-2008

Copyright © 9007-4

2 Replacing the blower motor [1] When replacing the blower motor, refer to Figure 3 to guide the power harness and position.

Blower motor

Power harness Locations of cooling hose & power harness for blower motor installation Bottom of case

Figure 3

MQ18001-003

[1] Install the blower motor after verifying the installation position in Figures 4 and 5.

> or = 2 mm (both side) Clearence between fan & case for blower motor installation Figure 4

MQ18001-004a

Blower motor

Unit case Align centers of blower fan & unit case Figure 5

MQ18001-004b

3 Replacing the evaporator 1.

Pull out the evaporator from under the unit case.

2.

Pull out the thermistor together with the sensor holder.

3.

Attach the sensor holder to the thermistor, then install the thermistor on the new evaporator in the location shown in Figure 6.

Second row of fins from bottom

Thermistor

Sensor holder

Figure 6

ASM-17-24-002

MQ18001-005

Issued 08-2008


Position the thermistor cord as shown in Figure 7, then install the evaporator at under the unit case.

Place thermistor cord along groove

Figure 7

MQ18001-006

4 Replacing the expansion valve 1.

Remove the pipe at the expansion valve inlet and the nut at the evaporator inlet.

2.

Peel off the insulation from the temperature sensor, remove the sensing tube, then remove the expansion valve from the evaporator.

3.

Install the new expansion valve on the evaporator to the specified torque. Tightening torque for the expansion valve inlet: 13.2 ± 1.5 Nm. Tightening torque for the evaporator inlet: 17.7 ± 2.0 Nm.

Fan motor side

NOTE: When installing the expansion valve, be careful not to put too much pressure on the O-ring. After sensing tube is installed

Evaporator side Applying insulation to temperature sensor Figure 8

MSM-17-18-001

MQ18001-007

Issued 08-2008

Copyright © 9007-6

5 Replacing the heater core 1.

Pull the heater core out from the unit case.

2.

Remove the bolts (5x12) from the pipe retainer and install it on the new heater core. Then install it under the unit case.

6 Replacing the motor actuator 1.

Push rod clamp A on the actuator lever in the direction of the arrow to remove it from the lever.

2.

Remove the 4 screws that hold the actuator in place.

3.

Install the lever on the new actuator, insert the rod into rod clamp and lock.

Figure 9

ASM-17-24-002

MQ18001-008

Issued 08-2008

Copyright ©

115

MULTI-PURPOSE + 3WAY VALVE

15

21

NOTES

72

1) UPPER VALUES IS MARK

, SHOW THE CONNECTIVE POINTS

AND LOWER VALUES SHOW THE ZONE NUMBER OF THIS DRAWING.

16

115

85

: OPTION PARTS

100

xx 114

For components description see section 8020

85

21

79

38

Y9 22

B32

75 B45 116 29

103 28

W1 W2 22

83

22 83

DOUBLE ACTING CIRCUIT

2 83 1

78

4

44

75

76

SECOND DOUBLE ACTING CIRCUIT

SINGLE ACTING CIRCUIT

B27 5 83

B26

MULTI-PURPOSE + 3WAY VALVE

78

97

102 51 104

60 95

85

55

10

85 99 94

85

93

Y26

Y25

96 53

96 B22

54 85

85

85

85

B22

CX80 TIER3 EXCAVATOR HYDRAULIC SCHEMATIC Pub. Number KAJ11600-E00 EN

Copyright ©

F34

K48

A11

F1

F3

F33

F27

K47 M20

G2

M10

E51

M1

P4 P5

K7 R1 G1

P10

Y2

K8

Y45

K34

S51

Y3 Y4

S1

Y22 H2

X2

B41

B81 K19

K18

K21

K4

K3

K20

K49

B47

E8 M4

Y25

B1

Y26 S16

P2

E3 E4

E2 B1

R3

S33

X8

S34

W1

B51

M14 P3

M3

S15 B21

B26 H4 R5

B27

NOTES 1) THE MARKS ARE INDICATED AS BELOW IN THIS DRAWING.

H5 S35

: OPTION PARTS

X15

U1

S6

: FOR CASE NORD AMERICA : FOR CASE EUROPA

B22

S13 S28

: FOR LBX

B22

2) EARTH LINE SYMBOLS AND CROSS POINT OF LINES IN THIS DRAWING SHOWS THE FOLLOWING.

B22

K5 H3

B22

A7

B2

CONNECTED EACH OTHER

NOT CONNECTED EACH OTHER

BODY EARTH

EARTH WITH CABLE

SINGLE WIRE CONNECTOR

HARNESS

3) THE SYMBOL AT EACH LINE SHOWS COLOR OF CABLE.

M7

M5

M6

THE FIGURE BEFORE THE SYMBOL SHOWS THE AREA OF CABLE. THE AREA OF CABLE NOT INDICATED IS 0,5 mm²

P6 K25

K24

K23

THE FIGURE AFTER THE SYMBOL SHOWS CIRCUIT N°.

K22 B45

60 B 001 AREA

CIRCUIT NUMBER

COLOR

S52

4) THE SYMBOL OF CONNECTOR IN THIS DRAWING SHOS THE FOLLOWING:

CONNECTOR (FEMALE)

CONNECTOR (MALE)

Y8 CONNECTOR' S NAME YAZAKI SWP (CN. xx)

E52

x

M8

R7

R4

A9

For components description see section 4020

CX80 TIER3 EXCAVATOR ELECTRICAL SCHEMATIC Pub. Number KAR11060-E00 EN

CONNECTOR. No

Case Crawler Excavator Cx75sr Cx80 Tier 3 Service Manual

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