REPAIR MANUAL
CX225SR
9-40691 1 02/12/2004
Contents INTRODUCTION DISTRIBUTION SYSTEMS POWER PRODUCTION TRAVELLING BODY AND STRUCTURE FRAME POSITIONING WORKING ARM TOOLS AND COUPLERS
A B D E F H J
9-40691 1 02/12/2004
INTRODUCTION
9-40691 1 02/12/2004 1
Contents INTRODUCTION Foreword ( - A.10.A.40)
3
CX225SR
Safety rules ( - A.50.A.10)
4
CX225SR
Basic instructions ( - A.90.A.05)
6
CX225SR
Torque ( - A.90.A.10)
7
CX225SR
Torque ( - A.90.A.10)
8
CX225SR
Dimension ( - A.92.A.30)
11
CX225SR
Weight ( - A.92.A.40)
12
CX225SR
Consumables ( - A.92.A.55)
13
CX225SR
Hydraulic contamination ( - A.92.A.60)
16
CX225SR
Product identication ( - A.80.A.10)
18
CX225SR WE
Product identication ( - A.80.A.10)
19
CX225SR NA
9-40691 1 02/12/2004 2
INTRODUCTION
Foreword ( - A.10.A.40) CX225SR
INTRODUCTION TO THE REPAIR MANUAL This manual has been designed so that in the near future it can be made available on CD and in a database via a computer network. This will allow fast and targeted search and navigation between the various information modules.
Information search
CRIL03J033E01
1
This manual is organised according to types of function and information. •
The function and information types are codied and appear in parentheses after the title and separated by a dash: (1) Function (2) Information type.
•
Only the rst letter (A) and the rst number (B) of the function need to be used for the information search. The rst letter (A) corresponds to the sections of the repair manual. The rst number (B) corresponds to the chapters of the repair manual. The rst part of the (A.B) code is reected in the page numbering. THE REST OF THE CODING IS NOT LISTED IN ALPHA-NUMERIC ORDER IN THIS MANUAL.
•
You will nd a table of contents at the beginning and end of each section and chapter. You will nd an alphabetical index at the end of each chapter.
•
Therefore it is the rst part of the (A.B) coding, then the tables of contents and index (page numbers) which will allow you to quickly nd the information you are looking for.
9-40691 1 02/12/2004 3
INTRODUCTION
Safety rules ( - A.50.A.10) CX225SR
CAUTION M171C - THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY. ATTENTION: To avoid injury, always observe the Safety Notices, CAUTION and ATTENTION, contained in this section and throughout the manual. Place a “Do not start the machine” warning notice on the starter switch key before all maintenance or repair operations.
CAUTION M489 - Read the operators manual to familiarize yourself with the correct control functions.
CAUTION M490 - Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury.
CAUTION M265A - A frequent cause of personal injury or death is persons falling off and being run over. Do not permit anyone to ride on the machine.
CAUTION SB055 - Before starting engine, study operators manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operation. It is your responsibility to understand and follow manufacturers instructions on machine operation, service, and to observe pertinent laws and regulation. Operators and service manuals can be obtained from your dealer. ATTENTION: You risk injury if you wear loose clothing or if you do not use safety equipment for your work. Always wear clothes which are unlikely to become caught in the machinery. Other safety equipment may be required, in particular: hard hat, safety boots, ear protectors, safety goggles or mask, thick gloves and reective clothing.
CAUTION M124A - Rotating machine parts, stay clear, keep shields installed to help protect from clothing entanglement and injury. Wear close-tted clothing.
CAUTION SB071 - Rotating fan and belts: Contact will cause injury. Keep clear. ATTENTION: Follow the procedures exactly when carrying out checks or inspections on the vehicle’s hydraulic systems. DO NOT CHANGE the procedures. ATTENTION: Before running the hydraulic cylinders in this vehicle through the cycles necessary for checking their functioning or for draining a circuit, warn people nearby to move away.
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INTRODUCTION
CAUTION SM121A - Always wear heat protective gloves to prevent burning your hands when handling heated parts.
CAUTION M132B - Lower or block elevated implements and other attachments before servicing or when leaving the equipment.
CAUTION R149C - Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting uid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking uid, see your doctor immediately. ATTENTION: To remove a hardened pin, such as a pivot pin, or a hardened shaft, use a soft-headed hammer (brass or bronze) or a brass or bronze peg and a steel-headed hammer.
CAUTION M428 - Always wear safety glasses when using a drill, hammer, saw, or other tools that may cause chips to y. ATTENTION: Use suitable servicing jacks or a chain hoist for raising the wheels or tracks. Always chock the vehicle in place with suitable safety supports. ATTENTION: When carrying out maintenance or repair operations on the vehicle, keep the workshop oor, the driving position and the steps free from oil, water, grease, tools, etc... Use an oil absorbent material and/or workshop cloths as necessary. Always use sound methods. ATTENTION: Some parts of this vehicle are very heavy. Use lifting devices or additional assistance recommended in the Operator’s Manual.
CAUTION M532 - Do not operate the engine in a closed building. Proper ventilation is required under all circumstances.
CAUTION M503 - 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.
CAUTION M244A - BATTERIES CONTAIN ACID AND EXPLOSIVE GAS. EXPLOSION CAN RESULT FROM SPARKS, FLAMES, OR WRONG CABLE CONNECTIONS. TO CONNECT JUMPER CABLES OR CHARGER, SEE MANUAL(S) FOR THE CORRECT PROCEDURE. FAILURE TO FOLLOW THE ABOVE INSTRUCTIONS CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH.
9-40691 1 02/12/2004 5
INTRODUCTION
Basic instructions ( - A.90.A.05) CX225SR
GENERAL Cleaning Clean all metal parts except the bearings with white spirit or steam. Do not use caustic soda for steam cleaning. After each cleaning, dry and oil all parts. Clean the oil ducts with compressed air. Clean the bearings with parafn, then dry them completely and lubricate them.
Inspection Check all the parts when they are disassembled. Replace all parts that show signs of wear or damage. Supercial scratches and grooves can be removed with an oil stone or with a cloth dipped in red oxide. A complete visual inspection is necessary to detect wear and pitting, and replacing parts as soon as it becomes necessary will help to avoid premature breakdowns.
Bearings Check that the bearings turn freely. Replace them if their adjustment is too free or if their functioning is irregular. Wash the bearings with a good solvent or parafn and allow them to air dry. DO NOT DRY THE BEARINGS WITH COMPRESSED AIR.
Needle bearings Before pushing needle bearings into a cylinder bore, always remove all metallic projections from the bore and its edges. Before pushing in bearings with a press, coat the inside and edges of the bearings with Vaseline.
Gears Check all the gears and ensure that they do not show any signs of wear or damage. Replace the worn out or damaged gears.
Gaskets, O-rings and at seals Always install new gaskets, O-rings, and at seals. Coat the gaskets and O-rings with Vaseline.
Shaft Check all shafts showing wear or damage. Enusre that the surface of a shaft carrying a bearing or gasket is not damaged.
Spare parts Always use CASE spare parts. To order these, refer to the Spare Parts Catalogue and indicate the correct reference number of the CASE spare parts. Breakdowns caused by the use of parts other than CASE spare parts are not covered by the warranty.
Lubrication Use only the oils and lubricants specied in the Operator’s Manual or the Service Manual. Breakdowns caused by the use of oils and lubricants not specically listed are not covered by the warranty.
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INTRODUCTION
Torque ( - A.90.A.10) CX225SR
STANDARD TIGHTENING TORQUE Order of tightening nuts and cap screws. Tighten alternately so that torque remains uniform. Cap screws which are tted with Loctite (look for traces of a white residue on the thread after removal), must be cleaned with a thin oil or a suitable solvent, then dried. Add two or three drops of Loctite to the cap screw thread, then t the screw.
CRIL03H012E01
1
The numbers in the diagrams represent the order of tightening.
Tightening torque Where there are no special instructions, tighten cap nuts screws to the torques given in the table below. Standard torque setting table. Designation of cap screws (dimensions) Cap screw Spanner in mm Torque setting in Nm Wrench in mm Socket head screw Torque setting in Nm
M6
M8
M10
M12
M14
M16
M18
M20
10 6.9
13 19.6
17 39.2
19 58.8
22 98.1
24 157.2
27 196
30 274
5 8.8
6 21.6
8 42.1
10 78.4
12 117.6
14 176.4
14 245
17 343
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INTRODUCTION
Torque ( - A.90.A.10) CX225SR
SPECIAL TORQUE SETTINGS No.
Component
Screw diameter Travel motor and reduction gear assembly M16 (1)* M16 (2)* Sprocket Idler wheel M16 (3)* Upper roller M20 (4)* Lower roller M18 (5)* M18 (6) Chain guide Track pad M20 (7) M36 (8) Counterweight M20 (9) Turntable (chassis) M20 (10) Turntable (upperstructure) M20 (11)* Swing motor and reduction gear assembly Engine M16 (12)* Engine mounts M10 (13)* Radiator M16 (14) Hydraulic pump M10 (15)* M20 Hydraulic reservoir M20 (16)* Fuel tank M20 (17)* M16 (18)* Control valve Hydraulic swivel M12 (19)* M16 (20) Cab Batteries M10 (21) Use Loctite 262 or an equivalent on mounting screws marked with an asterisk (*).
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Wrench in mm 24 24 24 30 27 27 30 55 30 30 30 24 17 24 17 30 30 30 24 19 24 17
Tightening torque 267 - 312 Nm 267 - 312 Nm 267 - 312 Nm 521 - 608 Nm 371 - 432 Nm 380 - 443 Nm 300 Nm+120 ° 2750 - 2940 Nm 468 - 545 Nm 468 - 545 Nm 521 - 608 Nm 265 - 313 Nm 64 - 74 Nm 147 - 176 Nm 64 - 74 Nm 367 - 496 Nm 412 - 471 Nm 412 - 471 Nm 267 - 312 Nm 109 - 127 Nm 78 - 80 Nm 20 - 29 Nm
INTRODUCTION
CRIL04B072H01
1
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INTRODUCTION
CRIL04B073H01
2
9-40691 1 02/12/2004 10
INTRODUCTION
Dimension ( - A.92.A.30) CX225SR
Machine ď€ tted with monobloc boom 5.70 m
CRPH04B001F00
1
Dippers
1.90 m 3.08 m 2.97 m 8.97 m 6.74 m 2.80 m 1.40 m 1.68 m 4.46 m 3.66 m 2.39 m 0.60 m 2.99 m 3.09 m 3.19 m 0.46 m 1.40 m
(A) (B) (C) (D) (E) (F) (G) (H) (I) (J) (K) (L) with track pads 600 mm (L) with track pads 700 mm (L) with track pads 800 mm (M) (N)
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2.40 m 3.14 m
3.00 m 2.90 m
8.93 m 6.70 m
8.85 m 6.62 m
INTRODUCTION
Weight ( - A.92.A.40) CX225SR
Weight of machine Weight
Conď€ guration With track pads 600 mm, monobloc boom 5.70 m, dipper 2.40 m, 760 kg backhoe, driver and full fuel tank
22 700 kg
Ground pressure 0.47 bar
Weight of components Engine Hydraulic pump Attachment control valve Swing moto-reduction gear Travel moto-reduction gear Boom cylinder Dipper cylinder Bucket cylinder Counterweight Cab Turntable Upperstructure with equipment (counterweight and turntable) Hydraulic swivel Undercarriage with equipment
Machine without equipment
Attachment Boom with equipment Dipper with equipment 3.00 m Dipper without equipment 3.00 m Radiator and oil-cooler assembly Fuel tank Hydraulic reservoir Idler wheel Upper roller Lower roller Tension shock absorber Track 600 mm Track 700 mm Track 800 mm
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487 kg 125 kg 187 kg 223 kg 250 kg 200 kg 257 kg 151 kg 5880 kg kg 244 kg 11770 kg 27 kg EUROPE 7020 kg NA 7730 kg EUROPE 18840 kg NA 19550 kg 3870 kg 2200 kg 910 kg 599 kg 55 kg 160 kg 145 kg 82 kg 17 kg 35 kg 142 kg 1350 kg 1570 kg 1710 kg
INTRODUCTION
Consumables ( - A.92.A.55) CX225SR
FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application. ATTENTION: You must respect the operating conditions for the different ingredients.
Hydraulic uid CASE AKCELA hydraulic uid is specially designed for high pressure applications and for the CASE hydraulic system. The type of uid to be used depends on the ambient temperature. •
TEMPERATE COUNTRIES - 20 °C to + 40 °C CASE AKCELA HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
•
HOT COUNTRIES 0 °C to + 60 °C CASE AKCELA HYDRAULIC EXCAVATOR FLUID "HOT CLIMATE" (MS 1230. ISO VG 100. DIN 51524 PART 2 HV)
•
COLD COUNTRIES - 40 °C to + 20 °C CASE AKCELA HYDRAULIC EXCAVATOR FLUID "COLD CLIMATE" (MS 1230. ISO VG 22. DIN 51524 PART 2 HV)
•
BIODEGRADABLE FLUID - 30 - +40 °C This yellow uid can be mixed with standard uid. If this liquid is used, it is advisable to completely drain the hydraulic circuit . CASE AKCELA HYDRAULIC EXCAVATORS FLUID BIO (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
Transmission component oil Extreme pressure oil used in transmission components inside sealed housings. CASE AKCELA 135H EP GEAR LUBE SAE 80W-90 (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)
Grease "Extreme Pressure" multi-purpose grease •
CASE AKCELA MOLY GREASE 241H EP-M (251H EP-M NLGI2) with lithium and molybdenum bisulphide soap.
•
CASE AKCELA 251H EP MULTI-PURPOSE GREASE (251H EP. NLGI 2) with lithium and calcium soap.
•
CASE AKCELA PREMIUM GREASE EP-2 (NLGI 2) with lithium soap.
HYDRAULIC HAMMERS Use only CASE AKCELA PREMIUM GREASE EP-2 (NLGI 2) grease with lithium soap.
Engine oil CASE AKCELA NO. 1 ENGINE OIL is recommended for the engine. This oil provides correct lubrication for your engine in all working conditions. If CASE AKCELA NO. 1 ENGINE OIL Multigrade cannot be obtained, use oil corresponding to one of the following categories: ACEA E5. MS 1121. API CH-4.
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INTRODUCTION
CRIL03H015F01
1
OIL USE RANGE 1.
Mineral-based
2.
Semi-synthetic based
3.
Synthetic based
Fuel Use fuel that is compliant with ASTM (American Society for Testing and Materials) standard D975. •
Use Grade No 2 fuel. The use of other types of fuel can result in a loss of power and may cause high fuel consumption.
•
When the temperature is very cold, the use of a mixture of No 1 and No 2 fuel is permitted. See your fuel vendor for winter fuel requirements in your area.
•
If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting.
IMPORTANT: In cold weather, ll the fuel tank at the end of the day’s work to prevent condensation from forming. FUEL STORAGE Long storage can lead to the accumulation of impurities and condensation in the fuel tank. 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 LRD -25°C For environments with temperatures falling to - 25 °C, do not mix with water. CASE AKCELA PREMIUM ANTI-FREEZE (MS 1710) For environments with temperatures falling to - 38 °C, use with water in a proportion of 50/50. IMPORTANT: Do not mix products of a different origin or a different make. The system must be topped up with the same product.
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INTRODUCTION
Environment Before carrying out any servicing operation on this machine and before disposing of used uids or lubricants, always think of the environment. Never throw uid or oil on the ground and never keep them in leaking receptacles. Contact your local ecological recycling centre for information on appropriate ways to dispose of these substances.
Components made from plastic or resin When cleaning plastic parts, (the console, the instrument panel, the indicators etc...) avoid using petrol, parafn, paint solvents etc. Use only water, soap and a soft cloth. The use of petrol, parafn, paint solvents, etc, will cause discoloration, cracking or deformation of these components.
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INTRODUCTION
Hydraulic contamination ( - A.92.A.60) CX225SR
CLEANING THE HYDRAULIC SYSTEM General Contamination of the hydraulic system is a major cause of incorrect operation of hydraulic components. Contamination is indicated by the presence of foreign particles in the hydraulic uid. Contamination of the hydraulic system can occur in any of the following situations: 1.
When draining the uid or disconnecting a hydraulic line.
2.
When disassembling a component.
3.
Due to normal component wear.
4.
Due to damaged or worn seals.
5.
Due to a damaged component in the hydraulic system.
All hydraulic systems can function even if they are slightly contaminated. The components of the hydraulic system are designed to support slight contamination. Any increase in the degree of contamination can cause serious problems in the hydraulic system. The following is an incomplete list of these problems: 1.
The cylinder rod seals leak.
2.
Control valve spools do not return to the neutral position.
3.
Control valve spools do not move easily.
4.
Hydraulic uid is too hot.
5.
Hydraulic components wear quickly.
6.
Safety valves or check valves do not close due to contamination.
7.
Repaired components break down soon.
8.
Cycles are slow; the machine does not have enough power.
If any of the above situations occurs, it is an indication of excessive contamination of the hydraulic system. To eliminate contamination, effectively, refer to PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating (A.10.A - F.30.A.60).
Types of contamination Contamination exists basically in two forms: microscopic or visible. We speak of microscopic contamination when very small particles of foreign bodies are in suspension in the hydraulic uid. These particles are too small to be seen or felt. Microscopic contamination can be detected by identifying the problems relating to microscopic contamination or by laboratory tests. The following are a few examples of problems caused by microscopic contamination: •
The cylinder rod seals leak.
•
Control valve spools do not return to the neutral position.
•
The operating temperature of the hydraulic system is too high.
•
Components wear quickly.
We speak of visible contamination when the presence of foreign bodies can be detected visually, by touch or by smell. Visible contamination can cause the sudden failure of a component. The following are a few examples of problems caused by visible contamination:
9-40691 1 02/12/2004 16
INTRODUCTION •
The uid contains metal or other fragments.
•
The uid contains air. The uid is dark and thick.
•
There is a smell of burning in the uid. The uid contains water.
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INTRODUCTION
Product identication ( - A.80.A.10) CX225SR WE
NOTE: For all parts orders, requests for information or assistance, always specify the type and the serial number of the machine to your CASE dealer. Fill out the following lines with the required information: type, year of manufacture, serial number of the machine (manufacturer’s plate), mark, type and serial number of the engine, and serial numbers of hydraulic components.
Manufacturer’s plate
CRIL03H001E01
(1) TYPE
1
(2) YEAR OF MANUFACTURE
(3) SERIAL NUMBER
Engine MAKE
TYPE
SERIAL NUMBER
Serial numbers of hydraulic components COMPONENTS Hydraulic pump Swing reduction gear Travel reduction gear Travel control valve Attachment control valve Swing control valve
SERIAL NUMBER
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INTRODUCTION
Product identication ( - A.80.A.10) CX225SR NA
NOTE: For all parts orders, requests for information or assistance, always specify the type and the serial number of the machine to your CASE dealer. Fill out the following lines with the required information: type, year of manufacture, serial number of the machine (manufacturer’s plate), make, type and serial number of the engine and serial numbers of hydraulic components.
Manufacturer’s plate
CRIL03I175E01
(1)TYPE
1
(2)YEAR OF MANUFACTURE
(3)SERIAL NUMBER
Engine MAKE
TYPE
SERIAL NUMBER
Serial numbers of hydraulic components COMPONENTS Hydraulic pump Swing reduction gear Travel reduction gear Travel control valve Attachment control valve Swing control valve
SERIAL NUMBER
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INTRODUCTION
9-40691 1 02/12/2004 20
REPAIR MANUAL DISTRIBUTION SYSTEMS
CX225SR
26019 1 02/12/2004 A
Contents DISTRIBUTION SYSTEMS - A
PRIMARY HYDRAULIC POWER SYSTEM
A.10.A
CX225SR
HYDRAULIC COMMAND SYSTEM
A.14.A
CX225SR
ELECTRICAL POWER SYSTEM
A.30.A
CX225SR
LIGHTING SYSTEM
A.40.A
CX225SR
26019 1 02/12/2004 A
DISTRIBUTION SYSTEMS - A PRIMARY HYDRAULIC POWER SYSTEM - 10.A
CX225SR
26020 1 02/12/2004 A.10.A / 1
Contents DISTRIBUTION SYSTEMS - A PRIMARY HYDRAULIC POWER SYSTEM - 10.A
TECHNICAL DATA PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10)
5
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10)
7
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A - D.20.A.40)
9
CX225SR WE
PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A - D.20.A.40)
11
CX225SR NA
PRIMARY HYDRAULIC POWER SYSTEM - Seed rates (A.10.A - D.50.A.60)
13
CX225SR
Hydraulic pump Hydraulic pump - Special tools (A.10.A.20 - D.20.A.40)
15
CX225SR
Hydraulic pump - Service limits (A.10.A.20 - D.20.A.20)
18
CX225SR
FUNCTIONAL DATA PRIMARY HYDRAULIC POWER SYSTEM - Static description (A.10.A - C.30.A.20)
19
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Dynamic description (A.10.A - C.30.A.10)
20
CX225SR
Stack valve Stack valve - External view (A.10.A.18 - C.10.A.40)
23
CX225SR
Stack valve - Sectional view (A.10.A.18 - C.10.A.30)
26
CX225SR
Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30)
31
CX225SR
Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30)
32
CX225SR
Hydraulic pump Hydraulic pump - Sectional view (A.10.A.20 - C.10.A.30)
33
CX225SR
Compensator Compensator - Sectional view (A.10.A.23 - C.10.A.30)
37
CX225SR
Sensing system Sensing system Temperature sensor - Electronic schema (A.10.A.95.90 - C.20.A.50) CX225SR
Powerboost system 26020 1 02/12/2004 A.10.A / 2
38
Powerboost system - Electronic schema (A.10.A.10 - C.20.A.50)
39
CX225SR
SERVICE PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A - F.35.A.40)
40
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A - F.35.A.51)
41
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
42
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25)
43
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Pressure test (A.10.A - F.40.A.30)
44
CX225SR
PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating (A.10.A - F.30.A.60)
46
CX225SR
Stack valve Stack valve - Remove (A.10.A.18 - F.10.A.10)
48
CX225SR
Stack valve - Overhaul (A.10.A.18 - F.10.A.40)
49
CX225SR
Stack valve Outlet section - Disassemble (A.10.A.18.20 - F.10.A.25)
50
CX225SR
Stack valve Inlet section - Disassemble (A.10.A.18.10 - F.10.A.25)
51
CX225SR
Stack valve - Visual inspection (A.10.A.18 - F.40.A.10)
52
CX225SR
Stack valve Inlet section - Assemble (A.10.A.18.10 - F.10.A.20)
53
CX225SR
Stack valve Outlet section - Assemble (A.10.A.18.20 - F.10.A.20)
54
CX225SR
Stack valve - Install (A.10.A.18 - F.10.A.15)
55
CX225SR
Relief valve Relief valve - Disassemble (A.10.A.16 - F.10.A.25)
56
CX225SR
Relief valve - Assemble (A.10.A.16 - F.10.A.20)
57
CX225SR
Relief valve - Pressure test (A.10.A.16 - F.40.A.30)
58
CX225SR
Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)
59
CX225SR
Powerboost system Powerboost system Electrovalve - Electrical test (A.10.A.10.15 - F.40.A.50)
60
CX225SR
Hydraulic pump Hydraulic pump - Remove (A.10.A.20 - F.10.A.10)
61
CX225SR
Hydraulic pump - Disassemble (A.10.A.20 - F.10.A.25)
63
CX225SR
Hydraulic pump - Assemble (A.10.A.20 - F.10.A.20) CX225SR
26020 1 02/12/2004 A.10.A / 3
70
Hydraulic pump - Install (A.10.A.20 - F.10.A.15)
80
CX225SR
Hydraulic pump - Bleed (A.10.A.20 - F.35.A.25)
82
CX225SR
Hydraulic pump - Pressure test (A.10.A.20 - F.40.A.30)
83
CX225SR
Reservoir Reservoir - Remove (A.10.A.22 - F.10.A.10)
84
CX225SR
Reservoir - Install (A.10.A.22 - F.10.A.15)
85
CX225SR
Compensator Compensator - Disassemble (A.10.A.23 - F.10.A.25)
86
CX225SR
Compensator - Assemble (A.10.A.23 - F.10.A.20)
87
CX225SR
Oil lter Oil lter - Remove (A.10.A.24 - F.10.A.10)
89
CX225SR
Oil lter - Install (A.10.A.24 - F.10.A.15)
90
CX225SR
Sensing system Sensing system Temperature sensor - Electrical test (A.10.A.95.90 - F.40.A.50)
91
CX225SR
DIAGNOSTIC PRIMARY HYDRAULIC POWER SYSTEM - Troubleshooting (A.10.A - G.40.A.10)
92
CX225SR
Stack valve Stack valve - Troubleshooting (A.10.A.18 - G.40.A.10)
92
CX225SR
Relief valve Relief valve - Troubleshooting (A.10.A.16 - G.40.A.10) CX225SR
26020 1 02/12/2004 A.10.A / 4
93
DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10) CX225SR
Capacities Total hydraulic circuit Hydraulic uid reservoir Coolant only
206 L 120 L 6.1 L
Main hydraulic pump Variable ow twin pump, with axial pistons. Maximum ow Displacement
2 x 190 L/min 2 x 96.7 cm³
Hydraulic control pump Fixed ow pump Maximum ow Displacement
22 L/min 11 cm³
Calibration pressure Pilot circuit main relief valve (± 1 bar) Main relief valve (standard) (± 3 bar) Main relief valve (power boost) (± 5 bar) Secondary relief valve (boom, dipper and bucket) ( ± 5 bar) Secondary relief valve (swing) (± 4 bar) Secondary relief valve (travel) (± 5 bar) Secondary relief valve (boom and dipper) (± 5 bar)
39 bar 343 bar 373 bar 392 bar 304 bar 343 bar 392 bar
Boom cylinder Barrel diameter Rod diameter Stroke
125 mm 90 mm 1284 mm
Dipper cylinder Barrel diameter Rod diameter Stroke
135 mm 95 mm 1474 mm
Bucket cylinder Barrel diameter Rod diameter Stroke
115 mm 80 mm 1012 mm
Cylinder leakage - attachment lowering (without load) Boom cylinders (rod retraction) Dipper cylinder (rod extension) Bucket cylinder (rod extension) Full (at the end of the attachment)
5 mm/5 mn 5 mm/5 mn 7 mm/5 mn 200 mm/10 mn
Cylinder speed Boom raising (bucket open and on the ground) Boom lowering (bucket open) Arm opening
3.5+/-0.6 s 2.9+/-0.6 s 2.7+/-0.6 s 26020 1 02/12/2004 A.10.A / 5
DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Arm closing Bucket opening Bucket closing
3.7+/-0.6 s 2.3+/-0.6 s 4+/-0.6 s
Control valve Five-section control valve for dipper, boom acceleration, swing, option and right travel. Four-section control valve for dipper acceleration, bucket, boom and left travel. Load holding relief valve for boom and dipper. Swing motor Fixed ow motor with axial pistons. Automatic disk brakes. 11.2 RPM 151 cm³ 155 L/min 16.757 857 Nm 32 bar 16 L/min
Chassis upperstructure swing speed Displacement Working ow Reduction ratio Braking torque Minimum brake release pressure Acceptable motor leakage Travel motor Two-speed motor with axial pistons. Automatic disk brakes. Slow speed High speed Gradeability Tractive effort Displacement Working ow Reduction ratio Braking torque (excluding reduction gear) Permissible deviation in travel over a distance of 20 m (full speed) Acceptable motor leakage
3.1 km/h 5 km/h 70 % (35°) 19 100 daN 168.9 cm³ 100.3 cm³ 212 L/min 43.246 483 Nm 1m 13 L/min
Attachment 13000 daN 9530 daN
Breakout force Breakout force (dipper 3 m)
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10) CX225SR
CRIL04B040H01
1
Location of secondary relief valves
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Calibration pressure Item
(H)
Nominal Pressure Secondary pressure with one relief pressure read on the turn of the machine screw setting (* or for a shim) 343 bar to 346 bar 217 bar Main relief valve(standard 120 L/min pressure) 290 bar Main relief valve (power boosted 373 bar to 373 bar 108 L/min pressure) Boom raising port secondary 392 bar to 405 bar 212 bar relief 20 L/min 392 bar to 405 bar Boom cylinder safety valves 20 L/min secondary relief Boom lowering port secondary 392 bar to 407 bar 212 bar relief 20 L/min 212 bar Dipper out port secondary relief 392 bar to 400 bar 20 L/min 392 bar to 400 bar Dipper cylinder safety valves 20 L/min secondary relief 392 bar to 400 bar 212 bar Dipper in port secondary relief 20 L/min Bucket open port secondary 392 bar to 408 bar 212 bar relief 20 L/min Bucket close port secondary 392 bar to 408 bar 212 bar relief 20 L/min 39 bar 43 bar 30 bar Pilot circuit main relief
(I)
RH swing port secondary relief
(J)
LH swing port secondary relief
(K)
(A)
(B) (B1) (B2) (C) (D) (D1) (E) (F) (G)
Description
325 bar
5 bar*
325 bar
5 bar*
Forward travel secondary relief
304 bar to 122 L/min 304 bar to 122 L/min 343 bar
343 bar
60 bar
(L)
Reverse travel secondary relief
343 bar
343 bar
60 bar
(N1) (N2)
Negative pressure of pump bodies (P1) and (P2) Pilot accumulator check
25.5 bar
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For pressure setting procedures, refer to:
Relief valve - Pressure setting (A.10.A.16 - F.45.A.70) Relief valve - Pressure setting (A.10.A.16 - F.45.A.70) Relief valve - Pressure test (H.20.B.16 - F.40.A.30) Safety valve - Pressure setting (H.20.B.15 - F.45.A.70) Relief valve - Pressure test (H.20.B.16 - F.40.A.30) Relief valve - Pressure test (H.25.B.16 - F.40.A.30) Safety valve - Pressure setting (H.25.B.15 - F.45.A.70) Relief valve - Pressure test (H.25.B.16 - F.40.A.30) Relief valve - Pressure test (H.30.C.16 - F.40.A.30) Relief valve - Pressure test (H.30.C.16 - F.40.A.30) Relief valve - Pressure test (A.14.A.16 - F.40.A.30) Relief valve - Pressure test (F.40.C.16 - F.40.A.30) Relief valve - Pressure test (F.40.C.16 - F.40.A.30) Relief valve - Pressure test (F.10.F.16 - F.40.A.30) Relief valve - Pressure test (F.10.F.16 - F.40.A.30) Hydraulic pump - Pressure test (A.10.A.20 - F.40.A.30) Accumulator - Check (A.14.A.30 - F.40.A.11)
DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A D.20.A.40) CX225SR WE
Digital tester assembly
CRIL03G253E00
1
DESCRIPTION Tester assembly for Multi-Handy 2051 Multi-Handy 2051 tester Pressure sensor (0 bar to 600 bar) Straight union for sensor Elbow union for sensor Engine speed sensor Cable (length 5 m) Electric plug 220 volts 50 Hz Cigarette lighter cable Instruction Sheet Carrying case
QUANTITY 1 2 2 1 1 3 1 1 1 1
CODE E54444449 D5444448 V5344460 W5344461 X5344462 Z5344463 E3144472 D5344467 E5344468 N5344476
QUANTITY 1 2 2
CODE RE3 Z5344486 D4323359 B8230183
The Multi-Handy tester is used to: Check pressure (two pressure scales) Check differential pressure (delta P) Check temperature Check engine rpm Check the ow 600 litre turbine
CRIL03G254E00
2
DESCRIPTION Turbine Plates M45x2 Flange diameter 24 mm
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM 4 8
Semi-ange Screw M12 length 75 mm
D4024267 Z1232983
Union assembly for testing pressure and ow
CRIL03G258E00
3
DESCRIPTION Union assembly for testing pressure and ow
CODE CAS30038
Set of high pressure hoses
CRIL03G259E00
4
DESCRIPTION Set of high pressure hoses
CODE CAS30036
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A D.20.A.40) CX225SR NA
Digital tester assembly for pressure measurement
CRIL03G255E00
1
DESCRIPTION Digital tester assembly for pressure measurement
CODE OEM1652
Digital tester assembly for pressure and temperature measurement
CRIL03G256E00
2
DESCRIPTION Digital tester assembly for pressure and temperature measurement
CODE OEM1653
Flowmeter
CRIL03G257E00
3
DESCRIPTION Flowmeter for a ow of < 75 GPM Flowmeter for a ow of > 75 GPM
CODE CAS10280 OEM1240
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Union assembly for testing pressure and ow
CRIL03G258E00
4
DESCRIPTION Union assembly for testing pressure and ow
CODE CAS40023A + CAS40035
Set of high pressure hoses
CRIL03G259E00
5
DESCRIPTION Set of high pressure hoses
CODE CAS30036
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Main pumps ow curve and pilot pressure "Negative ow control" diagram •
Engine speed 2000 RPM
•
Maximum displacement 96.7 cm³.
Hydraulic pump - Special tools (A.10.A.20 - D.20.A.40) CX225SR
NOTE: The tools listed below are to be manufactured locally. NOTE: Numbers in parentheses refer to Hydraulic pump - Sectional view (A.10.A.20 - C.10.A.30)
CRIL04B006E01
1
CRIL04B007E01
2
Used to install piston (69) and (70). (A) (B) (C) (D) (E) (F)
20 mm G1 diameter 23 mm 56 mm diameter 4 mm Number of coils: 7
Used to install pusher bracket (47). (A) (B) (C) (D)
50 mm M12 M12 G3/4
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
CRIL04B008E01
3
Used to install outer ring of taper roller bearing (4) on take-off shaft (3). (A) (B) (C) (D)
125 mm 105 mm diameter 46 mm diameter 56 mm
CRIL04B009E01
4
Used to protect seal (37) when reinstalling on seal holder (45). (A) (B) (C) (D) (E) (F) (G)
M8 95 mm 70 mm diameter 44 mm diameter 46 mm 69 mm 18 °
CRIL04B010E01
5
Used to install seal (37) on seal holder (45).
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
(A) (B) (C) (D) (E) (F) (G) (H)
53 mm 10 mm 12 mm 2 mm diameter 30 mm diameter 45 mm diameter 82 mm 30 °
CRIL04B011E01
6
Bushing (1) Used to calculate the thickness of shims (2). (A) (B) (C) (D) (E) (F)
diameter diameter 120 ° 18 mm diameter diameter
11 mm 116.5 mm
101 mm 134.5 mm
CRIL04B012E01
7
Bushing (2) Used to calculate the thickness of shims (2). (A) (B) (C)
20.5 mm diameter 84 mm diameter 99.4 mm
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Hydraulic pump - Service limits (A.10.A.20 - D.20.A.20) CX225SR
Description of parts Clearance between the piston and the cylinder bore Valve plate (sliding contact surface roughness) Cylidner barrel (sliding contact surface roughness) Swash plate (roughness) Piston assembly (roughness on contact surface of shoes) Clearance between pistons and shoes Scratches on the sliding surface of the shoes
Wear Limit
Action
0.04 mm or less
Control instrument Micrometer
Replace the cylinder assembly
0.8 Ra
Gauge
Polish the surface with a stone
0.4 Ra
Gauge
Polish the surface with a stone
0.8 Ra 0.8 Ra
Gauge Gauge
Polish the surface with a stone Polish the surface
0.4 mm or less
Gauge
Replace the parts
0.4 mm or more
Gauge
Replace the parts
Inspection of barrel, pistons and bearings Cylinder bores Pistons Taper roller bearings and needle bearings
Replace the cylinder barrel if the bores show signs of scratches or seizing. Replace any pistons showing signs of scratches or seizing. Replace any interior or exterior bearing rings showing signs of scratching.
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Static description (A.10.A - C.30.A.20) CX225SR
The hydraulic diagram is available as a poster at the end of this manual. For easier understanding, the same legend is used for components appearing in the hydraulic sections and on the poster.
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Dynamic description (A.10.A - C.30.A.10) CX225SR
TRAVEL Functions HIGH SPEED
Description High speed is obtained by changing the travel motors from large displacement to small displacement. When the pressure increases too much, the motors automatically change to low speed. When the pressure drops below 39 bar, the motors automatically change to high speed.
Refer to TRAVELLING Travel - Hydraulic schema (F.10.F - C.20.A.20)
LOW SPEED
Low speed is obtained when the travel motors are changed to high displacement. If you want to use the attachment or the swing during travel, the machine will continue in a straight line without zig-zagging.
TRAVELLING Travel - Hydraulic schema (F.10.F - C.20.A.20) TRAVELLING Travel - Hydraulic schema (F.10.F - C.20.A.20)
Description When the swing control is in the neutral position, the motor and reduction gear assembly is braked. When the swing is operated, the motor and reduction gear assembly brake is released. The swing is braked 5 seconds after putting the control into neutral or when the attachment is no longer operated. The swing torque is maintained by the priority valve incorporated in the control valve. When working in a trench, the swing variable priority valve is activated to provide sufcient ow to the dipper. This function reduces the number of rebounds when the swing is stopped. A protective valve is mounted on the swing motor.
Refer to SWINGING Circular swing Hydraulic schema (F.40.C C.20.A.20)
STRAIGHT-LINE TRAVEL
SWING Functions BRAKING
PRIORITY
ANTI-REBOUND
SWINGING Circular swing Hydraulic schema (F.40.C C.20.A.20) SWINGING Circular swing Hydraulic schema (F.40.C C.20.A.20)
ATTACHMENT Functions BOOM LIFTING
Description An internal spool is used to provide two ows when raising the boom. BOOM LOWERING, Boom lowering is made possible by unlocking the load holding system which is incorporated in the control valve. LOAD HOLDING BOOM LOWERING, Acceleration and ow reduction pressure information ADDITIONAL are controlled via the fuel return circuit in the boom SUPPLY valve spool and the continuous connection between the supply and the return. BOOM LOWERING, The pressure points are controlled by the circuit which keeps part of the supply ow for the free passage. This VIBRATION is used to reduce vibration. PREVENTION DIPPER OUT An internal spool provides two ows for the dipper. DIPPER IN, LOAD HOLDING DIPPER IN, ADDITIONAL SUPPLY
Refer to BOOM Lift - Hydraulic schema (H.20.B - C.20.A.20) BOOM Lift - Hydraulic schema (H.20.B - C.20.A.20) BOOM Lift - Hydraulic schema (H.20.B - C.20.A.20)
BOOM Lift - Hydraulic schema (H.20.B - C.20.A.20)
DIPPER Lift - Hydraulic schema (H.25.B - C.20.A.20) Dipper in is made possible by unlocking the load holding DIPPER Lift - Hydraulic schema system that is incorporated in the control valve. (H.25.B - C.20.A.20) The additional supply cancellation valve makes DIPPER Lift - Hydraulic schema combined movements quicker. (H.25.B - C.20.A.20)
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Stack valve - External view (A.10.A.18 - C.10.A.40) CX225SR
CRIL04A071G01b
1
Control valve block - Identiď&#x20AC; cation of ports Port (A1) (A3) (A6) (A8) (B2) (B5) (B7) (Dr) (P3-P3) (PT) (Pbu) (Pc2) (Ph) (T1-T2) (T4)
Description RH forward travel Swing left LH forward travel Boom raising Option circuit Arm closing Bucket opening Leak-off return Flow reinjection (option) Travel pressure switch Swing priority cancellation Boom load holding Main relief valve power boost Return By-pass return
Port (A2) (A5) (A7) (B1) (B3) (B6) (B8) (P1-P2) (PA) (PP) (Pc1) (Pc3) (Ps1-Ps2) (T3) (T5)
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Description Option circuit Arm opening Bucket closing RH reverse travel Swing right LH reverse travel Boom lowering Main pump pressure Attachment and swing pressure switch Pilot pump pressure Dipper load holding Priority to swing Negative pressure Swing return Towards cushion valve - heating
DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
CRIL04A88H01
2
Control valve block - description Description of control valve block (1) (32) (37) (52) (68)
Control valve block (P1) Valve Flange Flange Main safety valve
(13) (33) (43) (57) (69) 26020 1 02/12/2004 A.10.A / 24
Control valve block (P2) Spring Flange Spacer Secondary relief valve
DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM (72) (75) (77) (81) (88) (92) (96)
Plug Screw Control valve block xing screws Washer Cap Plug Plug
(74) (76) (78) (87) (89) (93) (A-A)
Spool cap screw Load holding valve xing screws Swing priority cap xing screws Plug Seal Plug Refer to Stack valve - Sectional view (A.10.A.18 - C.10.A.30) (B-B) Refer to Stack valve - Sectional view (A.10.A.18 - (M-M) Refer to Stack valve - Sectional view C.10.A.30) (A.10.A.18 - C.10.A.30)
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Stack valve - Sectional view (A.10.A.18 - C.10.A.30) CX225SR
CRIL04A089G01
1
Section A-A - Control valve block (P1) (5R) (8) (10) (14) (16) (41) (63)
Spool assembly - RH travel Large cap with pilot port Small cap Spool assembly - dipper 1 Spool assembly - swing Load holding valve watertight seal Port plug
(7) (9) (12) (15) (17) (42) (70)
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Seal Large cap Small cap with pilot port Spool assembly - boom 2 Spool assembly option (grab/hammer) Load holding valve watertight seal Negative pressure valve
DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
CRIL04A090G01
2
Section B-B - Control valve block (P2) (1) (3) (5L) (7) (9) (12) (42)
Control valve block (P2) Spool assembly - boom 1 Spool assembly - LH travel Seal Large cap Small cap with pilot orice Load holding valve watertight seal
(2) (4) (6) (8) (10) (41) (70)
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Spool assembly - dipper 2 Spool assembly - bucket Straight-line travel spool assembly Large cap with pilot orice Small cap Load holding valve watertight seal Negative pressure valve
DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
CRIL04A103G01
3
Section M-M - Watertight seal between the two control valve blocks (65)
Seal
(66)
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Seal
DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
CRIL04A102G01
4
Other sections Description Section (C-C) Output section with swing priority spool and dipper recycling valve Dipper section 1 and 2 (D-D) (E-E)
Boom 1 and 2 section
(F-F)
Swing and bucket section
(G-G)
Option and LH travel section
(H-H)
RH travel and straight-line spool section
(I-I)
Inlet section with main relief valve and check valves
Refer to Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30) Control valve - Sectional view (H.25.B.14 C.10.A.30) Control valve - Sectional view (H.20.B.14 C.10.A.30) Control valve - Sectional view (F.40.C.14 C.10.A.30) Control valve - Sectional view (H.30.C.13 C.10.A.30) Control valve - Sectional view (J.20.E.14 C.10.A.30) Control valve - Sectional view (F.10.F.14 C.10.A.30) Control valve - Sectional view (F.10.F.14 C.10.A.30) Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30)
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM (J-J)
Restrictor bridge (60) on port (PP) (pilot pressure) and port (PT) (upper pilot pressure switch)
(K-K)
Union (61) on port (PA) (travel pilot pressure switch)
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CRIL04A104A01
5
CRIL04A105A01
6
DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30) CX225SR
CRIL04A109G01
1
Section I-I (34) (35) (53) (54) (55) (68) (92)
Valve Spring Spacer Seal Back-up ring Main relief valve Plug
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30) CX225SR
CRIL04A110G01
1
Section C-C - Swing priority spool and dipper recycling valve. (18) (20) (22) (24) (26) (30) (32) (72)
Cap Spring seat Spool end Plug Spring Seal Valve Plug
(19) (21) (23) (25) (27) (31) (33)
Swing priority spool Spring Seal Seal Recycling spool Back-up ring Spring
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Hydraulic pump - Sectional view (A.10.A.20 - C.10.A.30) CX225SR
CRIL04A181H01
(1) (3) (5) (7)
Support Take-off shaft Screw Body
(2) (4) (6) (8)
1
Shim Taper roller bearing Support Swash plate
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM (9) (11) (13) (15) (17) (19) (21) (23) (25) (27) (29) (31) (33) (35) (37) (39) (41) (43)
Retaining plate Snap ring Seal Valve plate Screw Screw Coupling Spring Ring Seal Seal Seal Centring stud Spherical bushing Seal Driving shaft Regulator cartridge Safety block
(10) (12) (14) (16) (18) (20) (22) (24) (26) (28) (30) (32) (34) (36) (38) (40) (42) (44)
Piston Pinion Cylinder barrel Centring stud Needle roller bearing Seal Control pump Bushing Screw Plate Cover Valve plate Spring Seal Screw Regulator block Safety valve Regulator cartridge
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
CRIL04A182H01a
(45) (47) (49) (51) (53) (55) (57)
Seal carrier Pusher Spring seat Stop Seal Body Nut
(46) (48) (50) (52) (54) (56) (58)
2
Pusher bracket Piston Spring Seal Back-up ring Screw Spring
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM (59) (61) (63) (65) (67) (69) (71) (73)
Bushing Body Nut Seal Spring Piston Sleeve Pusher
(60) (62) (64) (66) (68) (70) (72) (74)
Seal Screw Stop Back-up ring Seal Piston Regulator block Swash plate
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Compensator - Sectional view (A.10.A.23 - C.10.A.30) CX225SR
CRIL04A100G01
(1) (3) (5) (7) (9) (11) (13) (15) (17) (19)
Control lever Centring stud Nut Stop Cover Spring seat Spool Body Cover Piston
(2) (4) (6) (8) (10) (12) (14) (16) (18)
1
Spring Spring Washer Spring guide Seal Liner Piston Seal Screw
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Sensing system Temperature sensor - Electronic schema (A.10.A.95.90 - C.20.A.50) CX225SR
CRIL03K145F01
1
Circuit layout (1)
Coolant temperature indicator
Audible alarm device (3) (B1) Coolant solution temperature sensor (B10) Hydraulic oil temperature thermo-switch
(2) (A2) (B9) (P1)
CRIL03G094E03
2
Timing diagram
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Coolant or hydraulic oil overheating indicator lamp Engine electronic control box Coolant solution temperature sensor Instrument panel
DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Powerboost system - Electronic schema (A.10.A.10 - C.20.A.50) CX225SR
CRIL04B074F01
1
Circuit layout (K28) (P1) (S29) (Y5)
Power boost solenoid valve relay Instrument panel Power boost switch Power-up solenoid valve (yellow band)
CRIL04B075F01
2
Timing diagram (1)
Operational power boost
OPERATION â&#x20AC;˘
When the power boost switch (S29) is operated, a signal is sent to instrument panel (P1). This activates relay (K28) and thus also power boost solenoid valve (Y5) for about 8 seconds. During these 8 seconds, the main relief valve is overcalibrated.
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A F.35.A.40) CX225SR
1.
Start the engine. The engine takes 10 to 15 minutes to warm up.
2.
With the engine running at full speed, operate the bucket and dipper controls in one direction (against the cylinder stops) for 30 seconds.
3.
Actuate the bucket and dipper control in the other direction (against the cylinder stops) for 30 seconds.
4.
Repeat steps 2 and 3 until the hydraulic temperature reaches 44 - 55 °C.
5.
Operate the boom, swing and travel controls in both directions to warm up all the circuits to 44 - 55 °C.
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A F.35.A.51) CX225SR
DANGER M252A - Hydraulic uid escaping under pressure can have enough force to penetrate the skin. Hydraulic uid may also infect a minor cut or opening in the skin. If injured by escaping uid, see a doctor at once. Serious infection or reaction can result if medical treatment is not given immediately. Make sure all connections are tight and that hoses and lines are in good condition before applying pressure to the system. Relieve all pressure before disconnecting the lines or performing other work on the hydraulic system. To nd a leak under pressure use a small piece of cardboard or wood. Never use hands. IMPORTANT: This operation must be carried out before any work is done on the hydraulic circuit. 1.
Park the machine on hard, at ground.
2.
Open the bucket until the cylinder rod is completely retracted.
3.
Extend the dipper until the cylinder rod is completely retracted. Lower the boom so that the end of the dipper is resting on the ground. Lower the tool to the ground.
4.
Slow the engine speed to idle for 30 seconds, then switch off the engine.
5.
Turn the starter switch key to "ON" without starting the engine.
6.
Lower the pilot control cancellation lever.
7.
Operate each control more than 10 times in both directions to release all pressure in the circuits.
8.
Press button (1) located on the hydraulic reservoir breather to release pressure in the reservoir.
CRIL04B099A01
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1
DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A F.35.A.20) CX225SR
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A - F.35.A.51) Prior operation: Fuel ller aid - Remove (B.20.A.20 - F.10.A.10) NOTE: It is recommended to install the vacuum pump before carrying out any work on the hydraulic circuit which requires opening the circuit. Installing this pump prevents uid loss when the circuit is opened. This chapter describes the procedure for installing vacuum pump CAS-10193. 1.
Remove plate (A) from the top of the hydraulic reservoir. Do not remove the reservoir seal.
CRIL04B100A01
2.
To install the adapter plate with elbow union, refer to PRIMARY HYDRAULIC POWER SYSTEM Special tools (A.10.A - D.20.A.40).
3.
Connect the vacuum pump to the adapter plate elbow union. Connect the vacuum pump harness to the batteries.
4.
Start the pump before carrying out any work on the circuit.
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25) CX225SR
IMPORTANT: A hydraulic component and the circuit must be bled after the component has been replaced. It is essential to ll the pump and motor housings and hydraulic components with oil before starting the machine. Failure to comply with these two recommendations may damage the component (overheating and seizing). IMPORTANT: Having bled the components, stop the engine for ve minutes and check for air bubbles in the hydraulic uid in the reservoir. 1.
To ll the housing and drain the hydraulic pump, refer to Hydraulic pump - Bleed (A.10.A.20 F.35.A.25)
2.
To bleed the attachment cylinders, extend and retract each cylinder rod four or ve times without bringing them up against the stops. Repeat the operation three or four times, this time bringing all the cylinder rods up against the stops.
3.
To ll the housing and bleed the hydraulic swing motor, refer to Hydraulic motor - Bleed (F.40.C.28 - F.35.A.25)
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Pressure test (A.10.A F.40.A.30) CX225SR
CRIL04B065G01
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Port identiď&#x20AC; cation marks Description of ports and insertion diameters, adjusting screws Port Screw (D1) (D2) (D3) (D4) (S1) (S2) (Pp) (Din3) (Dr) (Pd1) (Pd2) (Pd3) (Pi1) (Pi2)
Description Pump output (P2) Pump output (P1) Pilot pump output to Din3 Option pump output Main pump and pilot pump suction Option pump intake Pilot pump output Pilot pump output from D3 Leak-off circuit Plugged - Pressure test point Plugged - Pressure test point Plugged - Pressure test point Negative pressure Negative pressure
Location SAE 6000 psi 1" SAE 6000 psi 1" G 1/2 G 1/4 SAE 2000 psi 3" G 3/4 G 1/2 G 1/2 G 3/4 G 1/4 G 1/4 G 1/4 G 1/4 G 1/4
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Port Screw (H) (2) (3) (4) (5) (6) (7) (8) (9) (M1)
(M2)
Description
Location
Pilot pressure adjusting screw (main relief valve) Pump bleed screw Adjusting screw on large pump adjustment spring Adjusting screw on small pump adjustment spring Adjusting screw on large pump adjustment spring Adjusting screw on small pump adjustment spring Adjusting screw on retaining spring for maximum plate tilt on pump 1 Adjusting screw on retaining spring for maximum plate tilt on pump 2 Maximum stop adjusting screw pumps P1 and P2 Working pressure (port (Pd1) on main pump (D1)) •
LH travel
•
Boom
Bucket • Working pressure (port (Pd2) on main pump (D2)) •
R.H. travel
•
Swing
Dipper • (M3) Pilot pressure (port (Pd3) on pilot pump (D3) or port (P2) on the pilot circuit lter) For pressure setting values, refer to PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A D.40.A.10)
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating (A.10.A - F.30.A.60) CX225SR
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A - F.35.A.51) Prior operation: To remove the electric pump for lling with fuel, refer to Fuel ller aid - Remove (B.20.A.20 - F.10.A.10) Prior operation: To remove the protective panel from the hydraulic reservoir, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10) Prior operation: To remove the lower access panel to the hydraulic reservoir, refer to Protective shield - Remove (E.20.A.73 - F.10.A.10) 1.
2.
Prepare portable lter CAS10162A as follows: Expel all hydraulic uid from the portable lter inlet and outlet hoses. Remove the portable lter cartridge. Expel all hydraulic uid from the portable lter. Clean the interior of the cartridge housing. Install a new lter cartridge.
CRIL03I082A
1
CAS10508-3
2
Drain the hydraulic uid from the reservoir and clean the reservoir, see the Operator’s Manual.
NOTE: Do not re-install the drain plug on the hydraulic reservoir. 3.
Replace the breather element and the return lter and clean the intake lter, see the Operator’s Manual.
NOTE: Do not install the plate and the breather. 4.
Replace the pilot circuit lter, see the Operator’s Manual.
5.
Replace the Ultra Clean lter, see the Operator’s Manual.
6.
Install the valve from union kit (CAS 10508) on the reservoir drain port. Make sure that the valve is closed.
7.
Fill the hydraulic reservoir with clean hydraulic uid, see the Operator’s Manual.
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM 8.
Install the inlet hose from the portable lter on the valve under the hydraulic reservoir.
9.
Install the long pipe from union kit (CAS 10508) on the portable lter return hose.
10.
Pass the long pipe into the hydraulic reservoir via the breather port. Move the intake lter long pipe as far away as possible.
11.
Open the valve under the hydraulic reservoir.
12.
Install the portable lter on the upperstructure so that the machine can be operated. Attach the portable lter securely to the machine.
13.
Connect the portable lter electric cable to the battery. Make sure that the electric cable is away from all moving parts.
14.
Start the portable lter.
15.
Start the engine, run it at half speed for 10 minutes. During those ten minutes, stir the hydraulic uid in the hydraulic reservoir with the long pipe.
16.
Bring the hydraulic uid to its operating temperature, refer to PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A - F.35.A.40)
17.
With the engine idling, stir the hydraulic uid in the hydraulic reservoir for 10 minutes with the long pipe.
18.
Shut down the portable lter and the engine.
19.
Close the valve under the hydraulic reservoir.
20.
Remove the inlet pipe from the valve under the hydraulic reservoir.
21.
Remove the long pipe from the hydraulic reservoir.
22.
Disconnect the portable lter’s electric cable from the battery. Remove the portable lter from the machine.
23.
Install a vacuum pump on the hydraulic reservoir, refer to PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20) Start the vacuum pump.
24.
Remove the valve from underneath the reservoir and install the drain plug.
25.
Stop and remove the vacuum pump.
26.
Replace the return lter and clean the intake lter, see the Operator’s Manual.
27.
Replace the pilot circuit lter, see the Operator’s Manual.
28.
Replace the Ultra-Clean lter, see the Operator’s Manual.
29.
Check the hydraulic uid level. Top up as necessary, see the Operator’s Manual.
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Stack valve - Remove (A.10.A.18 - F.10.A.10) CX225SR
Prior operation: To remove the side protection panels from the hydraulic control valve, refer to Side shield Remove (E.20.A.70 - F.10.A.10) Prior operation: To remove the valve bank hood, the front protection panels from the hydraulic control valve and the valve bank hood bracket, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10) Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain ď&#x20AC;&#x201A;uid (A.10.A - F.35.A.20) 1.
Remove bracket ď&#x20AC; xtures (5), then remove the bracket.
2.
Mark the position of the hoses (1) and electrical connectors (2) on control valve block (3).
CRIL04C134B01
3.
Disconnect the electrical connectors (2) from the pressure switches.
4.
Disconnect and plug hoses (1).
5.
Plug the unions on control valve block (3).
6.
Attach a suitable lifting device to the control valve block (3).
7.
Remove screws and (4) control valve block (3).
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Stack valve - Overhaul (A.10.A.18 - F.10.A.40) CX225SR
NOTE: This section relates only to the control valve components not dealt with under functionalities. To ď&#x20AC; nd the functionalities, refer to Stack valve - Sectional view (A.10.A.18 - C.10.A.30) Other sections IMPORTANT: Clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18 F.40.A.10). 1.
To separate components (1) and (13), remove screws (77) and washers (81). Replace seals (65) and (66), refer to Stack valve - Sectional view (A.10.A.18 - C.10.A.30) section (M-M). When reassembling, tighten screws (77) to a torque of 167 - 177 Nm.
2.
Negative pressure valves (70) are not removable. Only the seals should be replaced. When reassembling, tighten valves (70) to a torque of 103 - 113 Nm.
3.
Tightening torques for the other components: Restrictor bridge (60) - 103 - 113 Nm. Plug (61) - 39 - 44 Nm. Plug (63) - 14 - 18 Nm. Plug (72) - 73 - 79 Nm.
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Stack valve Outlet section - Disassemble (A.10.A.18.20 - F.10.A.25) CX225SR
1.
SWING PRIORITY SPOOL Remove plug (72) and discard the seal. Remove spring (33) and valve (32). Remove screws (78) and cap (18). Discard seal (23). Remove complete spool (19). Remove screws from spool (22). Remove springs (21) and seats (20).
NOTE: To avoid abrasion of the spoolvsurface during dismantling of the spool assembly, use a soft-jawed vice and clamp the spool as closely as possible to the head in order to avoid any deformation. If the threaded part of the screw is coated with locking uid, heat the screw head with an industrial drier until it can be removed easily (usually the temperature should be 200 - 250 °C). If the spring is damaged (impaired functioning) during this operation, replace the spring. 2.
CRIL04B004A01
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CRIL04B005A01
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DIPPER RECYCLING VALVE Remove plug (24) and discard seal (25). Remove spring (26) and spool/liner assembly (27). Discard seals (30) and back-up rings (31).
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Stack valve Inlet section - Disassemble (A.10.A.18.10 - F.10.A.25) CX225SR
CRIL04A109G02
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Input section - cross-sectional view 1.
Remove plugs (72) and (92). Discard seals.
2.
Remove screws (75) and ï&#x20AC;&#x201A;anges (52). Extract spacers (53), springs (35) and valves (34). Discard seals (54) and back-up rings (55).
3.
Remove main relief valve (68).
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Stack valve - Visual inspection (A.10.A.18 - F.40.A.10) CX225SR
NOTE: Clean all parts with a suitable light oil based product. Allow to air dry and place each part on a clean sheet of paper or vinyl for inspection. NOTE: Inspect the surface of each part for scratches, abrasion and other damage. 1.
Check for scratches and dents on the check valve seats in the control valve body and for traces of rust and foreign matter.
2.
Check for scratches and dents on the outer surface of the spool. Remove small scratches with a piece of cloth soaked in an abrasive product.
3.
Check that all sliding surfaces move freely. Check for the absence of foreign matter in passages and grooves.
4.
Check for deformed or worn springs.
5.
Replace all seals and backup rings with new original parts.
6.
After removing the caps and plugs, make sure that there is no trace of paint on the body ports or the plug rims. (any trace of residual paint might lead to contamination, which could cause the system to malfunction and result in possible leaks).
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Stack valve Inlet section - Assemble (A.10.A.18.10 - F.10.A.20) CX225SR
Prior operation: To clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18 - F.40.A.10).
CRIL04A109G02
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Input section - cross-sectional view Torque settings Valve (68) Plug (72) Screw (75) Plug (92)
78 - 88 Nm 73 - 79 Nm 39 - 44 Nm 206 - 226 Nm
1.
Install plugs (72) and (92) with new seals. Tighten the plugs to the specied torque.
2.
Install valves (34) and springs (35). Install spacers (53) tted with seals (54) and new back-up rings (55). Install anges (52) with screws (75). Tighten the screws to the required torque.
3.
Install main relief valve (68) tted with a new seal. Tighten the valve to the required torque.
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Stack valve Outlet section - Assemble (A.10.A.18.20 - F.10.A.20) CX225SR
Prior operation: To clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18 - F.40.A.10). 1.
2.
3.
SWING PRIORITY SPOOL Install spring (33) and check valve (32). Install plug (72) with a new seal. Tighten the plug (72) to a torque of 73 - 79 Nm. Coat the threaded parts of spool (19) with thread locking uid. Clamp the end of the spool (spring side) in a soft-jawed vice. Install spring (21) and seats (20) on screw (22). Install and tighten screws (22) to a torque of 19 22 Nm. Fit complete spool (19) in the control valve. Fit a new seal (23) on cap (18). Install cap (18) with screws (78). Tighten screws (78) to a torque of 8.8 - 10.8 Nm.
CRIL04B004A01
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CRIL03L049A02
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CRIL04B005A01
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DIPPER RECYCLING VALVE Fit new seals (30) and (31) on liner (27B). Install piston (27C) and spool (27A) on liner (27B).
Fit spring (26) and spool/liner assembly (27). Install the plug (24) tted with a new seal (25). Tighten the plug to a torque of 103 - 113 Nm.
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Stack valve - Install (A.10.A.18 - F.10.A.15) CX225SR
1.
Using a lifting device, position control valve block (3) on its bracket.
CRIL04C134B01
2.
Coat ď&#x20AC; xing screws (4) with thread locking ď&#x20AC;&#x201A;uid and tighten them to a torque of 267 - 312 Nm. Remove the lifting device.
3.
Install and tighten supply and pilot hoses (1) on control valve block (3) following the marks made during removal.
4.
Attach electrical connectors (2) to the pressure switches following the marks made during removal.
5.
Mount bracket (5).
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Relief valve - Disassemble (A.10.A.16 - F.10.A.25) CX225SR
CRIL04A200F01
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Main relief valve (1) (3) (5) (7) (9) (11) (13) (15) (17) 1.
Nut Seal Spring Nut Seal Seal Seal Valve tip Valve
(2) (4) (6) (8) (10) (12) (14) (16)
Adjusting screw for standard pressure Piston Awl Adjusting screw for power boost pressure Valve body Check valve seat Back-up ring Spring
The valve is removed in the order of the marks on the parts.
NOTE: Valve seat (12) should not be removed. It is crimped to body (10).
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Relief valve - Assemble (A.10.A.16 - F.10.A.20) CX225SR
CRIL04A200F01
1
Main relief valve Refer to the disassembly process for a description of the parts.
1.
Clean the parts, coat the threads with hydraulic oil and replace the seals during assembly. The valve is re-assembled in the reverse order of the marks on the parts. When installing body (10) on the control valve, tighten it to a torque of 78 - 88 Nm.
Next operation: Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)
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