Case Crawler Excavator Cx75sr Cx80 Tier 3 Service Manual [PDF]

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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.

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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.

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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.

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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.

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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.

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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

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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

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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

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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................................................................................................................................................................

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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).

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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

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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

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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 fol- low 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 sup- plying 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.

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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.

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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

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-12

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

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-15

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)

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-16

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

Lep SC75SRCX80-1002-0EN

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)

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)

Secondary pressure (MPa)

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

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-18

Operating torque (Nm) (lbf-ft)

Secondary pressure (MPa)

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)

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-19

Secondary pressure (MPa)

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)

Lep SC75SRCX80-1002-0EN

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)

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-21

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

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-22

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

CX75SR Model

MONO BOOM

Boom length Arm type

OFFSET BOOM

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

Long 2.120 mm (83.46 in)

Standard 1.750 mm (68.90 in)

1710 mm (67.32 in)

2120 mm (83.46 in)

1740 mm (68.50 in)

Bucket capacity

Heaped 0.28 m3 (Leveled 0.20 m3)

Heaped 0.22 m3 (Leveled 0.16 m3)

Heaped 0.28 m3 (Leveled 0.20 m3)

Bucket width

730 mm (28.74 in)

600 mm (23.62 in)

730 mm (28.74 in)

Bucket width with side cutter

804 mm (31.65 in)

673 mm (26.50 in)

804 mm (31.65 in)

Bucket weight with side cutter

204 kg (449.74 lb)

178 kg (392.42 lb)

204 kg (449.74 lb)

1450 mm (57.08 in)

1050 mm (41.34 in)

1450 mm (57.08 in)

Arm (dipper) length

Bucket radius Bucket wrist action

177°

Maximum digging radius

6520 mm (256.69 in)

6900 mm (271.65 in)

6080 mm (239.40 in)

Maximum digging radius at ground line

6390 mm (251.57 in)

6770 mm (266.53 in)

6360 mm (250.39 in)

Maximum digging depth

4140 mm (162.99 in)

4540 mm (178.74 in)

4190 mm (164.96 in)

Maximum vertical straight wall digging radius

3640 mm (143.31 in)

4100 mm (161.42 in)

4580 mm (180.31 in)

Maximum digging height

7330 mm (288.58 in)

7620 mm (300 in)

7195 mm (283.27 in)

Maximum dump height

5250 mm (206.69 in)

5540 mm (218.10 in)

5150 mm (202.75 in)

Minimum swing radius at front

1785 mm (70.27 in)

2085 mm (82.08 in)

2230 mm (87.79 in)

Height for minimum swing radius at front

5620 mm (221.26 in)

5650 mm (222.44 in)

5700 mm (224.41 in)

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-23

CX80 Model

MONO BOOM

Boom length Arm type

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

Long 2.120 mm (83.46 in)

1710 mm (67.32 in)

2120 mm (83.46 in)

Bucket capacity

Heaped 0.28 m3 (Leveled 0.20 m3)

Heaped 0.22 m3 (Leveled 0.16 m3)

Bucket width

730 mm (28.74 in)

600 mm (23.62 in)

Bucket width with side cutter

804 mm (31.65 in)

673 mm (26.50 in)

Bucket weight with side cutter

204 kg (449.74 lb)

178 kg (392.42 lb)

1050 mm (41.34 in)

1050 mm (41.34 in)

Arm (dipper) length

Bucket radius Bucket wrist angle

177°

Maximum digging radius

7030 mm ( 276.77 in)

7400 mm (291.33 in)

Maximum digging radius at ground line

6390 mm (275.19 in)

7270 mm (286.21 in)

Maximum digging depth

4180 mm (164.56 in)

4590 mm (180.70 in)

Maximum vertical straight wall digging radius

3080 mm (121.25 in)

3550 mm (139.76 in)

Maximum digging height

6390 mm (251.57 in)

6600 mm (259.84 in)

Maximum dump height

4390 mm (172.83 in)

4600 mm (181.10 in)

Minimum swing radius at front

2750 mm (108.26 in)

2910 mm (114.56 in)

Height for minimum swing radius at front

5060 mm (199.21 in)

5080 mm (199.99 in)

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-24

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

(OFFSET BOOM)

AQ29001-001_EU

Weight (kg) information is approximate Symbol

Component Name

MONO BOOM SPEC.

OFFSET BOOM SPEC.

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)

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-25

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)

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-26

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

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-27

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

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-28

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

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-29

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.

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-30

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

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-31

Track

Øf

Øf' d

c

Øe'

Øe

Øg'

Øg h

h

b

a

AQ19002-004A

Mark a b c d

Lep SC75SRCX80-1002-0EN

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

Copyright © 1002-32

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)

Lep SC75SRCX80-1002-0EN

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

Issued 03-08

Copyright © 1002-33

2. Boom cylinder foot/Frame a b

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

Dimension (mm) 91 92 90 88 1.0 to 3.5 Shims 65 64 65 66.5

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

Lep SC75SRCX80-1002-0EN

Dimension (mm) 91 87 90 88 0.5 to 3.5 Shims 65 64 65 66.5

Issued 03-08

Copyright © 1002-34

4. Dipper cylinder foot/Boom Mark

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

Dimension (mm) 81 87 80 78 0.5 to 3.0 Shims 60 59 60 61.5

AQ19002-011A

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-35

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

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-36

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

Lep SC75SRCX80-1002-0EN

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

Copyright © 1002-37

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)

Dimension (mm) Standard Limit Standard Limit

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

c (a - b)

Lep SC75SRCX80-1002-0EN

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

Issued 03-08

Copyright © 1002-38

2.Base Boom/Offset cylinder/Rod h

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

Dimension (mm) Standard Limit Standard Limit

f (play) g (shaft)

0.5 to 3.0 Shims 55 54

h (bushing off- Standard set cylinder) Limit

55 56.5

Standard Limit

55 56.5

i (bushing rod)

3. Offset Boom/ Offset cylinder

c

b

a

Øe Ød

AQ19002-020A

Mark a (offset boom) b (offset cylinder)

Dimension (mm) Standard Limit

71 77

Standard Limit

70 68

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

c (play)

Lep SC75SRCX80-1002-0EN

0.5 to 3.0 Shims 55 54 55 56.5

Issued 03-08

Copyright © 1002-39

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

c

b (rod) b

a c (a - b) Ø d (shaft)

c

Ød Øe

Ø e (bushing rod)

Dimension (mm) Standard Limit

158 164

Standard Limit Standard Limit Standard Limit Standard Limit

157 155 0.5 to 3.0 Shims 55 54 55 56.5

AQ19002-021A

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

b a

c (play) c

Ø d (shaft)

d e AQ19002-022A

Ø e (bushing offset boom)

Dimension (mm) Standard Limit

281 287

Standard Limit

280 278

Standard Limit Standard Limit Standard Limit

0.5 to 1.5 Shims 100 99 100 101.5

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

a b c

d

c (a - b)

e

Ø d (shaft)

AQ19002-023A

Lep SC75SRCX80-1002-0EN

Ø e (bushing dipper cylinder)

Dimension (mm) Standard Limit

251 257

Standard Limit

250 248

Standard Limit Standard Limit Standard Limit

0.5 to 3.0 Shims 60 59 60 61.5

Issued 03-08

Copyright © 1002-40

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

a b

Dimension (mm) Standard Limit

Standard Limit Standard c (a - b) Limit Standard 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

Dimension (mm) Standard Limit Standard Limit

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)

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

c (play)

Ød

Dimension (mm) Standard Limit Standard Limit

Øe

c

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

AQ19002-026A

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-41

DIMENSIONS AND WEAR LIMITS OF BLADE AND BLADE CYLINDER

10

11

12 AQ19002-027A

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

Øe

c (play) d (shaft)

b a

c

e (bushing)

Dimension (mm) Standard Limit Standard Limit

71 77 70 68

Standard Limit Standard Limit Standard Limit

1.0 to 2.5 Shims 55 54 55 56.5

AQ19002-028A

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

b a

Øe

c

Dimension (mm) Standard Limit Standard Limit

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

c (play)

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

AQ19002-029A

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-42

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

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-43

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

I.D.

O.D.

Shim Thickness

Material

KMV0650

30.2

50

0.4

SPCC

KMV0651

30.2

50

0.8

SPCC

KMV0652

30.2

50

1.6

SPHC

KMV0653

30.2

50

3.2

SPHC

KMV0654

30.2

50

4.5

SS00

KMV0655

30.2

50

6.0

SS00

KMV0912

32

45

0.4

SPCC

KMV0913

32

45

0.8

SPCC

KMV0914

32

45

1.2

SPCC

KHV0327

36

65

1.2

SPHC

KHV0316

36

70

1.2

SPHC

KHV0315

41

75

1.2

SPHC

KHV0324

41

80

1.2

SPHC

KHV0317

41

90

1.2

SPHC

KAV0058

43

90

1.6

SPHC

KHV0347

46

80

1.2

SPHC

KAV0180

46

80

1.6

SPHC

KAV0682

46

90

1.2

SPHC

KHV0299

46

100

1.2

SPHC

KHV0328

51

85

1.2

SPHC

KAV0160

51

85

1.6

SPHC

BHV1030

51

90

1.2

SPHC

BHV1031

51

90

2.6

SPHC

KHV0330

51

95

1.2

SPHC

KAV0813

51

100

1.2

SPHC

KAV1951

51

100

2.6

SPHC

KAV0061

51

101.6

1.6

SPHC

KHV0348

51

105

1.2

SPHC

KAV0805

51

120

1.2

SPHC

KAV0812

56

90

1.2

SPHC

KAV0558

56

100

1.2

SPHC

BHV1033

56

100

2.6

SPHC

KHV0298

56

105

1.2

SPHC

KAV0395

56

110

0.8

SPHC

KAV0060

56

110

1.6

SPHC

KAV0396

56

115

1.2

SPHC

KAV0427

56

120

1.2

SPHC

KMV0771

60.5

76

1.2

SPHC

KAV0161

61

90

1.6

SPHC

Lep SC75SRCX80-1002-0EN

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

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-45 (Units: mm) Part No.

I.D.

O.D.

Shim Thickness

Material

KSP0408

81

200

1.2

SPHC

KSP0409

81

200

2.6

SPHC

KBV0122

82

120

3.2

SS00

KBV0123

82

120

4.5

SS00

KBV0124

82

120

6.0

SS400

KBV0373

82

180

1.0

SPCC

KRV1178

86

130

1.2

SPHC

KRV1585

86

150

1.2

SPHC

KHV0170

86

150

1.2

SPHC

KBV0389

87

210

1.0

SPCC

KBV0390

87

210

1.6

SPCC

BHV1030

90

51

1.2

SPHC

KBV0837

91

135

1.2

SPHC

KSV0477

91

145

1.2

SPHC

KSP0411

91

145

2.6

SPHC

KMV0121

91

159

1.2

SPHC

KBV0769

91

160

1.2

SPHC

KSP0269

91

160

2.6

SPHC

KBV0764

91

165

1.2

SPHC

KRV0559

91

180

1.2

SPHC

KRV1180

91

190

1.2

SPHC

KSP0412

91

200

1.2

SPHC

KSP0413

91

200

2.6

SPHC

KBV0381

92

180

1.0

SPCC

KBV0382

92

180

1.6

SPCC

KBV0383

92

180

2.0

SPCC

KBV0384

92

180

3.2

SS00

KBV0377

92

220

1.0

SPCC

KBV1749

96

140

1.2

SPHC

KNV0468

96

150

1.2

SPHC

KSP0828

96

150

1.2

SPHC

KBV1629

96

170

1.2

SPHC

KBV0361

97

250

1.0

SPCC

KBV0362

97

250

1.6

SPCC

BHV1032

100

56

1.2

SPHC

KSV0478

101

160

1.2

SPHC

KSP0415

101

160

2.6

SPHC

KSP0416

101

180

1.2

SPHC

KSP0417

101

180

2.6

SPHC

KBV0474

101

219

1.2

SPHC

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-46 (Units: mm) Part No.

I.D.

O.D.

Shim Thickness

Material

KBV0369

102

210

1.0

SPCC

KSV0138

103

190

1.2

SPHC

KSV0139

103

190

2.6

SPHC

KSV0140

103

190

3.2

SS00

KSV0135

103

213

1.2

SPHC

KSV0136

103

213

2.6

SPHC

KSV0137

103

213

3.2

SS00

KSP0827

106

170

1.2

SPHC

KHV0190

111

150

1.2

SPHC

KSP0418

111

180

1.2

SPHC

KSP0419

111

180

2.6

SPHC

KTV0533

111

190

1.2

SPHC

KSV0476

111

230

1.2

SPHC

KBV0214

112

150

6.0

SS400

KBV0215

112

150

9.0

SS400

KBV0357

112

270

1.0

SPCC

KHV0193

121

155

1.2

SPHC

KMV1517

121

220

0.4

SPHC

KMV1518

121

220

0.6

SPHC

KMV1519

121

220

0.8

SPHC

KHV0296

121

230

1.2

SPHC

KTV0534

121

250

1.2

SPHC

KWV0101

131

170

1.2

SPHC

KSV0839

131

200

1.2

SPHC

KHV0287

131

240

1.2

SPHC

KTV0850

141

225

1.2

SPHC

KHV0297

141

240

1.2

SPHC

KHV0288

151

300

1.2

SPHC

KUV0080

171

280

1.2

SPHC

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-47

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

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-48

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

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-49

SPECIAL TORQUE SETTINGS CX75SR No.

Component

Screw

Wrench (mm)

Torque setting

1*

Travel motor and reduction gear assembly

M16

24

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

2*

Drive sprocket

M14

22

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

3*

Idler wheel

M10

17

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

4*

Upper roller

M16

24

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

5*

Lower roller

M20

30

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

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 (*).

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-50

16

21

17

13

18

20 11 12

7 14 15 10

19

10 6

1 7 2 5 4

8,9

3

1 , 2 2

FRONT

3 , 4 , 5 ,

1

7

6

3 4

5

6

7 AQ09002-001

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-51

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

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-52

SPECIAL TORQUE SETTINGS CX80 No.

Component

Screw

Wrench (mm)

Torque setting

1*

Travel motor and reduction gear assembly

M16

24

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

2*

Drive sprocket

M14

22

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

3*

Idler wheel

M10

17

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

4*

Upper roller

M16

24

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

5*

Lower roller

M20

30

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

6*

Front guard

M16

24

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

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 (*).

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-53

FRONT

FRONT

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-54

FRONT

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-55

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

2. Long Arm (2.12 m)

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-56

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)

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-57

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

Lep SC75SRCX80-1002-0EN

Issued 03-08

Copyright © 1002-58

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

Lep SC75SRCX80-1002-0EN

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

Copyright © 3001-2

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

Lep SM75SR3001-0EN

Issued 08-2008

Copyright © 3001-3

FUEL TANK See detail A

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

Lep SC75SRCX80-4001-0EN

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

Copyright © 4001-2

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

Lep SC75SRCX80-4001-0EN

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.

Lep SC75SRCX80-4001-0EN

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

Lep SC75SRCX80-4001-0EN

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

Lep SC75SRCX80-4001-0EN

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.

Lep SC75SRCX80-4001-0EN

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

Lep SC75SRCX80-4001-0EN

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.

Lep SC75SRCX80-4001-0EN

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).

Lep SC75SRCX80-4001-0EN

Issued 03-08

Copyright © 4001-10 [2]

One-touch idling POWER SUPPLY 24V

MONITOR

THROTTLE VOLUME

ONE-TOUCH IDLING SWITCH

GND GND

CONTROL DEVICE

DC MOTOR

PULL CABLE

GOVERNOR LEVER SPRING CHAMBER

IDLING ADJUSTMENT SCREW

THROTTLE VOLUME POWER SUPPLY MONITOR CONTROL DEVICE

5V

ONE-TOUCH IDLING SWITCH

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.

Lep SC75SRCX80-4001-0EN

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.

Boost Pressure (KPa)

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)

Lep SC75SRCX80-4001-0EN

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

Boost Pressure (KPa)

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

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 -1)

Lep SC75SRCX80-4001-0EN

1820 1850 AQ28002-027A

Issued 03-08

Copyright © 4001-13

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

MONITOR

RELAY SOLENOID

TRAVEL CHANGEOVER SWITCH

2) Operation

TRAVEL CHANGEOVER SWITCH MONITOR OUTPUT

RESET LIGHTS ON LIGHTS OUT

LED DISPLAY LAMP CHECK

LAMP CHECK

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

Lep SC75SRCX80-4001-0EN

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.

Lep SC75SRCX80-4001-0EN

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.

Lep SC75SRCX80-4001-0EN

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.

Lep SC75SRCX80-4001-0EN

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)

Lep SC75SRCX80-4001-0EN

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.

Lep SC75SRCX80-4001-0EN

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.

Lep SC75SRCX80-4001-0EN

Issued 03-08

Copyright © 4001-20

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

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

OVERHEAT SIGNAL

THERMO-SWITCH (OIL)

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

50 {122}

80 {176}

100 {212}

120 {248}

Resistance (ohm)

153.9

32.3

18.4

16.1

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

105 {221}

Thermostat switch (oil) specifications

Lep SC75SRCX80-4001-0EN

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.

Lep SC75SRCX80-4001-0EN

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.

Lep SC75SRCX80-4001-0EN

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.

Lep SC75SRCX80-4001-0EN

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.

Lep SC75SRCX80-4001-0EN

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

Lep SC75SRCX80-4001-0EN

Issued 03-08

Copyright © 4001-26

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

Lep SC75SRCX80-4001-0EN

Issued 03-08

Copyright ©

Section 4020

CNH

Lep SC75SRCX80-4020-0EN

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

4020

ELECTRICAL EQUIPEMENT & ELECTRIC CIRCUIT DIAGRAMS

Copyright © 4020-2

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

Lep SC75SRCX80-4020-0EN

Issued 03-08

Copyright © 4020-3

Lep SC75SRCX80-4020-0EN

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)

Lep SC75SRCX80-4020-0EN

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

Lep SC75SRCX80-4020-0EN

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

Lep SC75SRCX80-4020-0EN

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

Lep SC75SRCX80-4020-0EN

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

Lep SC75SRCX80-4020-0EN

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

Lep SC75SRCX80-4020-0EN

2B 700 2B 600

2B 700 2B 600

VR 196

A9

AO30001-004

Copyright © 4020-10

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

Lep SC75SRCX80-4020-0EN

Issued 03-08

Copyright © 4020-11

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

DESCRIPTION

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

MARKING POSITION ; FIT THE HARNESS'S WHITE TAPE

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

QTY

PRESS. SWITCH

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

Lep SC75SRCX80-4020-0EN

Issued 03-08

Copyright © 4020-12

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

Lep SC75SRCX80-4020-0EN

Issued 03-08

Copyright © 4020-13

Electrical Components and Wiring for Upper Frame (engine) DESCRIPTION

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

CN189 RING TERMINAL M4 (GLOW)

CN196 RING TERMINAL M4 (OIL PRESS SWITCH)

THERMO SENSOR

SYM

QTY

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

Lep SC75SRCX80-4020-0EN

Issued 03-08

Copyright © 4020-14

Electrical Components and Wiring for Upper Frame (battery)

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

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

Lep SC75SRCX80-4020-0EN

Issued 03-08

Copyright © 4020-15

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

WHITE MARKING

HEATER(ENG.RETURN)

DETAIL-A

IN CONNECT HEATER UNIT

OUT CONNECT HEATER UNIT

HEATER(ENG.RETURN)

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

DETAIL-A

KAR10850-D00

Lep SC75SRCX80-4020-0EN

Issued 03-08

Copyright © 4020-16

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

Lep SC75SRCX80-4020-0EN

Issued 03-08

Copyright © 4020-17

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

Lep SC75SRCX80-4020-0EN

Issued 03-08

Copyright © 4020-18

ELECTRICAL CONNECTOR WIRING DIAGRAM Main Frame Harness (CX75SR)

CMF7M

KAR10690-E00

Lep SC75SRCX80-4020-0EN

Issued 03-08

Copyright © 4020-19

Main Frame Harness (CX80)

CMF7M (FUSIBLE LIMK (FUSE BOX))

Lep SC75SRCX80-4020-0EN

Issued 03-08

Copyright © 4020-20

Cab Main Harness (inside cab)

CN28F (AIRCON CONTROLER AMP 2)

CN29F

KAR10710-E00

Lep SC75SRCX80-4020-0EN

Issued 03-08

5001

Copyright ©

Section 5001 REMOVAL AND INSTALLATION OF THE TRACKS

CNH

Lep SM75SR5001-0EN

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

Copyright © 5001-2

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

Lep SM75SR5001-0EN

Issued 08-2008

Copyright © 5001-3

TRACK SHOE 1

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

Copyright © 5003-2

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

-## 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

Copyright © 8014-14 No.

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

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

8015

8005

Copyright © 8015-2

TABLE OF CONTENTS SOLENOID VALVE.................................................................................................................................................. 3 ASSEMBLY DRAWINGS ........................................................................................................................................... 3 THEORY OF OPERATION ......................................................................................................................................... 4 MAINTENANCE ...................................................................................................................................................... 4 Assembling and disassembling precautions ..................................................................................................... 4 Assembling and Disassembling a Solenoid Operated Directional Valve .......................................................... 4 Maintenance Standards .................................................................................................................................... 6 Troubleshooting ................................................................................................................................................ 6

Lep SM75SR8015-0EN

Issued 08-2008

Copyright © 8015-3

SOLENOID VALVE 1 Assembly drawings

Normally closed type solenoid: SP, S1

Normally open type solenoid: S2 MQ26001-002

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

Body (1) Spool (2) Spool (1) Spring (2) Spring (1) Adaptor (3) Snap ring(3) Name plate(1) Spring washer (6)

MSM-17-26-001

10. 11. 12. 13. 14. 15. 16. 17. 18.

Binding band (blue) (1) Binding band (red) (1) Binding band (pink) (1) Solenoid (3) O-ring (3) Hexagon socket head bolt (6) Plug (4) Plug (4) Rivet (2)

Issued 08-2008

Copyright © 8012-4

2 Theory of operation The hydraulic fluid supplied from the port P is fed to the solenoid operated directional valves S1 @ when the valve SP is energized. The hydraulic fluid is then fed to the ports C1 depending on whether or not the valves S1 is energized. Electromagnetic selector valves S1: Oil passes through when energized Electromagnetic selector valves S2: Oil passes through when not energized

NN16001-002

3 Maintenance 1 Assembling and disassembling precautions [1] Disassemble the valve with due attention not to damage the O-ring and other parts, and store the parts in a safe place. [2] If there is any flaw on the O-ring, replace it with a new one. [3] Be careful to assemble the parts in the correct orientation and without forgetting any of the parts. [4] When assembling, reverse the order of disassembling and pay attention not to allow any foreign matters such as dirt to get into the valve. 2 Assembling and Disassembling a Solenoid Operated Directional Valve [1] Remove the mounting bolts from the solenoid (C) and remove the coil part. (Tool: 3 mm Hexagon wrench) [2] Remove the tube, while paying attention not to damage the edges of the flat portion of the core. However, if the core is removed, replace the O-ring (A) with a new one. (Tool: 23 mm spanner) [3] Take out the spools (2) and (3) and the springs (4) and (5). [4] Pry the snap ring (7) off by inserting a flat head screwdriver or the like in the notch, and remove the adapter (6). [5] Assemble the valve by reversing the order of disassembling. When tightening the core, pay attention not to damage the edges of the flat portion of the core. When mounting the adaptor, apply grease or other appropriate lubricant to the O-ring (B) and pay attention not to damage the O-ring.

MSM-17-26-001

Issued 08-2008

Copyright © 8015-5

1.7VQ2.0 Nm

O-ring SO-NA-A022

14.4VQ17.6 Nm

O-ring SO-NB-P18

Item 2 assembly: electronic selector valve SP, S1 Item 3 assembly: electronic selector valve S2 NN16001-003

MSM-17-26-001

Issued 08-2008

Copyright © 8012-6 3 Maintenance Standards

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

Copyright © 8016-2

TABLE OF CONTENTS CUSHION VALVE.................................................................................................................................................... 3 STRUCTURE .......................................................................................................................................................... 3 OPERATIONAL DESCRIPTION .................................................................................................................................. 4 DISASSEMBLY AND ASSEMBLY .............................................................................................................................. 5 General Precautions ......................................................................................................................................... 5 Disassembling procedures ................................................................................................................................ 5 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

Figure 1 AQ27002-001

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

Spring Orifice Body Connector Sleeve Plunger Name plate

ASM-17-24-002

8. 10. 11. 12. 13. 15.

Ring Snap ring O-ring O-ring O-ring Plunger assembly

Issued 08-2008

Copyright © 8016-4

2 Operational description A -> B: Flow control (Figure 2) • • • • • •

Hydraulic oil supplied from port A passes through orifice (2) and the hole around plunger (6) and drains out to port B. At this time, the resistance of oil passing through orifice (2) causes the pressure in chamber (1) to become greater than the pressure in chamber (2). The plunger therefore moves to the right. As plunger (6) moves to the right, section (I) is closed, creating a blind circuit, and the pressure in chambers (1) and (2) is equalized. As the pressure in chambers (1) and (2) is equalized, the force of spring (1) returns plunger (6) to the neutral position. Repetition of this process causes plunger (6) to be balanced in a position where the force of spring (1) and the resistance of orifice (2) are equal. (As the flow rate through orifice (2) increases and the resistance increases, section (I) closes). FS = FA - FB (FA = P1 x a > P2 x b = FB)

•

FS:

force of spring (1)

FA:

force to push the plunger to the right

FB:

force to push the plunger to the left

P1:

pressure in chamber (1)

P2:

pressure in chamber (2)

a, b:

outer diameter of plunger (a = b)

Consequently, a flow rate of oil passing through orifice (2) necessary to generate a passing resistance that balances the force of spring (1), is maintained, controlling the flow rate from port A into port B at a constant level. 6

1

5

b

A

2

a

3

(1)

(I)

B

(2)

Figure 2 AQ27002-002

ASM-17-24-002

Issued 08-2008

Copyright © 8016-5 B -> A: Free flow (Figure 3) • • • •

Hydraulic oil supplied from port B first passes through orifice (2) and drains out to port A. Resistance of oil passing through orifice (2) causes the pressure in chamber (1) to become less than the pressure in chamber (2), moving plunger (6) to the left. As plunger (6) moves to the left, section (II) opens and hydraulic oil passes through the circuit in section (II) and the opening around plunger (6), and the entire flow drains out to port A. When the supply of hydraulic oil is cut, plunger (6) is returned to the neutral position by the force of the 2 springs (1). 3

5

6

b

A

2

a

1

(1)

(II)

B

(2)

Figure 3 AQ27002-003

3 Disassembly and Assembly 1 General Precautions • Hydraulic valves all consist of precision components. Disassemble and assemble them in a clean area that is free of dust. Use clean tools and solvent. • After disassembly, clean parts and apply a corrosion inhibitor. • During disassembly, number each part to ensure that it is reassembled into its original position. • When reassembling, clean each part well, remove foreign substances, and verify that parts have no burrs or dents. If burrs/dents are found, remove them with an oil stone. • Replace all seals with new ones each time the hydraulic valve is disassembled. • When reassembling, apply hydraulic oil to sliding parts and a thin coating of grease to all seals. • Never attempt to forcibly hit or pry parts when they cannot be moved easily. 2 Disassembling procedures (Reassembly is done in the reverse order of disassembly.) [1] • • •

See figure 4 Remove snap ring (10). Remove sleeve (5). Remove O-rings (13). (x 2) 13

5

10

Figure 4 AQ27002-004

ASM-17-24-002

Issued 08-2008

Copyright © 8016-6 [2] See figure 5 • Disconnect connector (4). Tightening torque of connector (4): 24.5 ± 2.9 Nm • Remove O-ring (11). 11

4

Figure 5 AQ27002-005

[3] • • • •

See figure 6 Remove spring (1). Remove the plunger assembly (15). [Orifice (2) and ring (8) cannot be disassembled.] Remove spring (1). Remove O-ring (12). Plunger assembly (15) must be oriented correctly at reassembly. (Install so that ring (8) is visible when viewed from the port A side.) 1

15

12

1

3

Figure 6 AQ27002-006

3 Troubleshooting Symptom External oil leak

Unstable flow rate at A -> B Oil flow of B -> A blocked from running its entire volume

ASM-17-24-002

Cause Scratches on O-ring seal surfaces at each port. O-ring breakage. Spring (1) is fatigued or breakage. Foreign substance lodged in plunger assembly (15). Foreign substance blocking in orifice (2). Foreign substance lodged in plunger assembly (15).

Solution Repair or replace Replace Replace spring (1) Disassemble to clean and repair or replace. Disassemble and clean. Disassemble to clean and repair or replace.

Issued 08-2008

Copyright ©

Section 8018

8018

DISASSEMBLY AND REASSEMBLY OF THE HYDRAULIC SWIVEL

CNH

Lep SM75SR8018-0EN

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

Copyright © 8018-2

TABLE OF CONTENTS ROTATING JOINT ................................................................................................................................................... 3 COMPONENT DIAGRAM .......................................................................................................................................... 3 TOOLS AND JIGS ................................................................................................................................................... 4 DISASSEMBLY INSTRUCTIONS ................................................................................................................................ 5 ASSEMBLY INSTRUCTIONS ..................................................................................................................................... 7 ASSEMBLY DRAWINGS ........................................................................................................................................... 9

Lep SM75SR8018-0EN

Issued 08-2008

Copyright © 8018-3

ROTATING JOINT 1 Component diagram

1 2 5 3 4

10 11

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

Axle V-ring O-ring Paking ring Rotor Cover

ASM-17-17-002

9 7. 8. 9. 10. 11.

AQ17002-001

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

Copyright © 8018-6 4.

Push out the axle (1) from the rotor (5) using a jig.

NOTE: Do not hit the parts with a hammer while carrying out this operation.

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

Copyright © 8018-8 4.

Install the V-ring (2) to the axle (1), and apply plenty of grease. Ensure that no water or dirt mixes into the grease

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

Copyright © 8018-10

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

Issued 08-2008

Copyright ©

Section 8019

8019

DISASSEMBLY AND ASSEMBLY OF THE SWING MOTOR

CNH

Lep SM75SR8019-0EN

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

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

Copyright © 8019-6 Problem

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

Copyright © 8019-7 Problem

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

Copyright © 8019-9 Problem

Cause

Remedy

1. Worn abrasive material on disks.

Replace disks with new ones.

2. Fatigue or breakage of springs in piston section.

Replace springs with new ones.

3. Faulty sliding section or warping in brake piston, or deformation of abrasive face of disk.

Repair sliding face, or replace parts if damage is serious. Surfaces of abrasive material cannot be repaired.

4. Timer valve does not switch over and pressure cannot be released from cylinder chamber (models with hydraulic timer specifications only). 2. Poor braking power. No braking power.

1) Valve spring fatigue.

1) Replace spring.

2) (Models with hydraulic timer specifications only:) Signal pressure SH is supplied or signal system back pressure is high. 3) For other problems, see 1.3. 1) - 3).

2) Check pressure in SH signal system. If back pressure is high, take measures to reduce to specified value.

5. Pressure cannot be released from cylinder chamber because of blockages in orifice and filter.

3) For other problems, see 1.3. 1) - 3).

Clean filter and orifice, or replace with new ones.

1. Brake piston rubs on disk because release pressure PB (PG) is low. 2. Decreased pressure in cylinder chamber due to abnormal wear or breakage of O-ring in brake piston.

3. Parking brake does not release completely, generating noises, vibratory shocks, abnormalities and heat.

3. For malfunctioning timer valve, see 2.4. 1) - 3). 4. Faulty hydraulic timer section. (Models with hydraulic timer specifications only:) Parking brake operates as a dynamic brake because timer is set too early. 1) Orifice is not positioned correctly. 2) Faulty valve seat. 3) Foreign substances engaged in the above valve seat. 4) Spring fatigue or breakage.

ASM-17-22-002

1) Disassemble to inspect valve, then assemble orifice correctly. 2) If abnormal damage is found on seat surface, repair or replace with new one. 3) Clean new parts and remove foreign substances. 4) Replace spring with new one.

Issued 08-2008

Copyright © 8019-10 2 Tools used No

Name

1

Plastic hammer Hexagon wrench

2

Screwdriver (flathead)

3

Snap ring pliers (internal)

4

Snap ring pliers (external)

5

Hand press

6

Vise

Description and remarks

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

Copyright © 8019-21

!

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

1-1

1-7

1-8

1-9

1-10

1-5

1-6 1-4

6) Remove collar (1-10) and plate (1-9). 1-2

1-3 AQ22002-030

7) Remove pinion shaft (1-2). NOTE: When removing the shaft, be careful not to let it fall. If it is hard to remove, tap it lightly with a plastic hammer.

1-2

AQ22002-031

8) Remove the inner race of tapered roller bearing (1-8). 1-8

AQ22002-032

ASM-17-22-002

Issued 08-2008

Copyright © 8019-22 9) Break oil seal (1-7) and remove. NOTE: Oil seals that have been removed cannot be reused. Be careful not to damage the outer races of tapered roller bearings (1-6, 1-8) during removal.

1-7

AQ22002-033

10) Remove plug (1-35).

1-35

AQ22002-034

ASM-17-22-002

Issued 08-2008

Copyright © 8019-23 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

ASM-17-22-002

Issued 08-2008

Copyright © 8019-27 15 Install greased O-rings (2-27-6-7, 15, 17) and backup rings (2-27-6-16, 18) on relief valve (2-27-6), and then install it on cover (2-27-1).

2-27-6-7

2-27-6-18

2-27-6-16 2-27-6-3

Tightening torque: 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

Copyright © 8019-29

1 Press fit oil seal (1-7). Press fitting dimension: 4.25 (shown in the figure to the left). Prior to press fitting, apply grease to the mounting site of the oil seal in the housing and the outer surface of the oil seal. (Reference jig No. 23).

Dimension of oil seal after press fitting: 4.25

2 Assembling the reduction gears (reference) 1-7

AQ22002-059

2 Apply grease to the inner race of tapered roller bearing (1-6), which is installed in pinion shaft (1-2). Amount of grease packed: 80 to 90 cm2 (approx. 66 to 75 g).

1-2

1-6

AQ22002-060

ASM-17-22-002

Issued 08-2008

Copyright © 8019-30 3 Install pinion shaft (1-2), etc. Install inner race of tapered roller bearing (1-8). Apply grease to lip of oil seal (1-7) before installing pinion shaft (1-2), etc. Before installing pinion shaft, verify that plug (1-35) is not attached. Installing the pinion shaft with the plug attached increases the air pressure inside, and this may cause damage to oil seal (1-7).

1-7

1-8

1-2

AQ22002-061

4 Install collar (1-10) while applying load 1177ON to the inner race of tapered roller bearing (1-8). (Reference jig No. 24) Apply grease to O-ring (1-36) and install on plug (1-35). Install plug in housing (1-1).

1-1

1-8

1-9

1-10

Tightening torque: 15.7±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