Case cx80 crawler excavator service repair manual by 1639701yu

REPAIR MANUAL

CX75SR CX80

9-93290 2 14/12/2004

Contents INTRODUCTION DISTRIBUTION SYSTEMS POWER PRODUCTION TRAVELLING BODY AND STRUCTURE FRAME POSITIONING WORKING ARM TOOLS AND COUPLERS

A B D E F H J

9-93290 2 14/12/2004

INTRODUCTION

9-93290 2 14/12/2004 1

Contents INTRODUCTION Foreword ( - A.10.A.40)

CX75SR, CX80

Safety rules ( - A.50.A.10)

CX75SR, CX80

Basic instructions ( - A.90.A.05)

CX75SR, CX80

Torque ( - A.90.A.10)

CX75SR

Torque ( - A.90.A.10)

CX80

Dimension ( - A.92.A.30)

CX75SR

Dimension ( - A.92.A.30)

CX80

Weight ( - A.92.A.40)

CX75SR

Weight ( - A.92.A.40)

CX80

Consumables ( - A.92.A.55)

CX75SR, CX80

Hydraulic contamination ( - A.92.A.60)

CX75SR, CX80

Product identication ( - A.80.A.10)

CX75SR WE, CX80 WE

Product identication ( - A.80.A.10)

CX75SR NA, CX80 NA

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INTRODUCTION

Foreword ( - A.10.A.40) CX75SR, CX80

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

This manual is organised according to types of function and information. •

The function and information types are codied 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 reected 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.

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INTRODUCTION

Safety rules ( - A.50.A.10) CX75SR, CX80

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 reective 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.

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INTRODUCTION

Basic instructions ( - A.90.A.05) CX75SR, CX80

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 parafn, 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. Supercial 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 parafn 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 specied in the Operator’s Manual or the Service Manual. Breakdowns caused by the use of oils and lubricants not specically listed are not covered by the warranty.

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INTRODUCTION

Torque ( - A.90.A.10) CX75SR

Order of tightening nuts and cap screws. Tighten alternately so that torque setting remains even. 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

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) Wrench in mm Cap screw Torque setting in Nm Wrench in mm Socket head screw Torque setting in Nm

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

SPECIAL TORQUE SETTINGS No. (1)* (2)* (3)* (4)* (5)* (6) (7) (8) (9)* (10)* (11)* (12) (13)* (14)* (15)* (16)*

Component Travel moto-reduction gear Sprocket Idler wheel Upper roller Lower roller Track pad Counterweight Turntable bearing (chassis and upperstructure) Swing moto-reduction gear Engine Engine mounts Radiator Hydraulic pump Hydraulic pump support Hydraulic reservoir Fuel tank 9-93290 2 14/12/2004 7

Screw diameter M16 M14 M10 M16 M20 M14 M24 M16 M16 M16 M10 M12 M10 M12 M12 M10

Wrench in mm 24 22 17 24 30 22 36 24 24 24 17 19 17 Hex 19 17

Tightening torque 267 - 312 Nm 173 - 202 Nm 63 - 73 Nm 267 - 312 Nm 521 - 608 Nm 220 - 270 Nm 850 - 992 Nm 252 - 283 Nm 267 - 312 Nm 265 - 313 Nm 64 - 74 Nm 36 - 44 Nm 64 - 74 Nm 109 - 126 Nm 69 - 78 Nm 36 - 44 Nm

INTRODUCTION No.

Wrench Screw in mm diameter M12 19 (17)* Control valve Hydraulic swivel M10 17 (18)* M16 24 (19) Cab Use Loctite 262 or an equivalent on mounting screws marked with an asterisk (*). Component

CRIL03H14G01

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Tightening torque 53 - 64 Nm 63 - 73 Nm 78 - 80 Nm

INTRODUCTION

CRIL03H13H01

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INTRODUCTION

Torque ( - A.90.A.10) CX80

CRIL03H012E01

The numbers in the diagrams represent the order of tightening.

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

SPECIAL TORQUE SETTINGS No. (1)* (2)* (3)* (4)* (5)* (6) (7) (8) (9)* (10)* (11)* (12) (13)* (14)* (15)* (16)*

Screw diameter M16 M14 M10 M16 M20 M14 M24 M16 M16 M16 M10 M12 M10 M12 M12 M12

Wrench in mm 24 22 17 24 30 22 36 24 24 24 17 19 17 Hex 19 19

Tightening torque 267 - 312 Nm 173 - 202 Nm 63 - 73 Nm 267 - 312 Nm 521 - 608 Nm 220 - 270 Nm 850 - 992 Nm 252 - 283 Nm 267 - 312 Nm 265 - 313 Nm 64 - 74 Nm 36 - 44 Nm 64 - 74 Nm 109 - 126 Nm 107.9 Nm 107.9 Nm

INTRODUCTION No.

Wrench Screw in mm diameter M12 19 (17)* Control valve Hydraulic swivel M10 17 (18)* M16 24 (19) Cab Use Loctite 262 or an equivalent on mounting screws marked with an asterisk (*). Component

CRIL04F009G01c

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Tightening torque 53 - 64 Nm 63 - 73 Nm 78 - 80 Nm

INTRODUCTION

CRIL04F010H01

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INTRODUCTION

Dimension ( - A.92.A.30) CX75SR

Machine ď&#x20AC; tted with monoblock boom + dozer blade

CRIL03G042G01

Monobloc boom + dozer blade 1,71m dipper (A) (B) (C) (D) (E) (F)

2.69 m 2.70 m 5.915 m 1.42 m 2.22 m 0.74 m

(G) (H) (I) (J) (K) (L)

1.21 2.84 2.21 1.87 0.45 2.32

m m m m m m

(M) (N) (P) (Q) (R) (S)

0.36 4.49 1.16 1.06 2.32 0.45

m m m m m m

(G) (H) (I)

1.21 m 2.84 m 2.21 m

(M) (N) (P)

0.36 m 4.485 m 1.16 m

2.12 m dipper (A) (B) (C)

2.95 m 2.70 m 5.910 m

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INTRODUCTION (D) (E) (F)

1.42 m 2.22 m 0.74 m

(J) (K) (L)

1.87 m 0.45 m 2.32 m

1.06 m 2.32 m 0.45 m

(Q) (R) (S)

Machine ď&#x20AC; tted with offset backhoe boom + dozer blade

CRIL03G043G01

Offset backhoe boom + dozer blade 1.75 m dipper (A) (B) (C) (D) (E) (F) (G)

2.97 2.70 5.97 1.42 2.22 0.74 1.21

m m m m m m m

(H) (I) (J) (K) (L) (M) (N)

2.84 2.21 1.87 0.45 2.32 0.36 4.54

m m m m m m m

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(P) (Q) (R) (S) (T) (U) (V)

1.16 m 1.06 m 2.32 m 0.45 m 1m 1.1 m 0.18 m

INTRODUCTION

Dimension ( - A.92.A.30) CX80

Machine ď&#x20AC; tted with monobloc boom 3,50 m + dozer blade

CRIL04E060G01

Monobloc boom + dozer blade 1.70 m dipper (A) (B) (C) (D) (E) (F)

2.33 m 2.70 m 6.425 m 1.425 m 2.225 m 0.745 m

(G) (H) (I) (J) (K) (L)

1.63 2.85 2.21 1.87 0.45 2.32

m m m m m m

(M) (N) (P) (Q) (R) (S)

0.36 m 5m 1.16 m 1.065 m 2.32 m 0m

(G) (H) (I)

1.63 m 2.85 m 2.21 m

(M) (N) (P)

0.36 m 5.09 m 1.16 m

2.10 m dipper (A) (B) (C)

2.65 m 2.70 m 6.510 m

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INTRODUCTION (D) (E) (F)

1.425 m 2.225 m 0.745 m

(J) (K) (L)

1.87 m 0.45 m 2.32 m

1.065 m 2.32 m 0.45 m

(Q) (R) (S)

1.75 m dipper (A) (B) (C) (D) (E) (F) (G)

2.97 2.70 5.97 1.42 2.22 0.74 1.21

m m m m m m m

(H) (I) (J) (K) (L) (M) (N)

2.84 2.21 1.87 0.45 2.32 0.36 4.54

m m m m m m m

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(P) (Q) (R) (S) (T) (U) (V)

1.16 m 1.06 m 2.32 m 0.45 m 1m 1.1 m 0.18 m

INTRODUCTION

Weight ( - A.92.A.40) CX75SR

Weight of components Mono boom dozer blade Engine Hydraulic pump Attachment control valve Swing motor and reduction gear assembly Travel motor and reduction gear assembly Boom cylinder Dipper cylinder Bucket cylinder Dozer blade cylinder Offset backhoe dipper cylinder Offset backhoe boom cylinder Counterweight Cab Turntable Upperstructure assembly Hydraulic swivel Undercarriage assembly Machine without attachment Attachment Boom assembly Dipper assembly Dozer blade Radiator and oil-cooler assembly Fuel tank Hydraulic reservoir Idler wheel Upper roller Lower roller Tension shock absorber Track 450 mm Track 600 mm

Offset backhoe boom dozer blade

260 kg 54 kg 88 kg 80 kg 81 kg 103 kg 78 kg 51 kg 34 kg 81 kg 41 kg 1210 kg kg 92 kg 4780 kg 40 kg 2790 kg 6500 kg 1090 kg 620 kg 260 kg 330 kg 25,5 kg 11 kg 54 kg 44 kg 4 kg 14 kg 37 kg 425 kg 502 kg

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5190 kg

1490 kg 1020 kg

INTRODUCTION

Weight ( - A.92.A.40) CX80

Weight of components Mono boom dozer blade 260 kg 51 kg 88 kg 80 kg 81 kg 103 kg 78 kg 51 kg 34 kg 56 kg 1220 kg XXX kg 92 kg 4430 kg 40 kg 2790 kg 6900 kg 1390 kg 1060 kg 260 kg 330 kg 35 kg 47.3 kg 54.2 kg 45 kg 4 kg 14 kg 37 kg 425 kg 502 kg

Engine Hydraulic pump Attachment control valve Swing moto-reduction gear Travel moto-reduction gear Boom cylinder Dipper cylinder Bucket cylinder Dozer blade cylinder Offset cylinder Counterweight Cab Turntable Upperstructure assembly Hydraulic swivel Undercarriage assembly Machine without equipment Attachment Boom assembly Dipper assembly Dozer blade Radiator and oil-cooler assembly Fuel tank Hydraulic reservoir Idler wheel Upper roller Lower roller Tension shock absorber Track 450 mm Track 600 mm

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INTRODUCTION

Consumables ( - A.92.A.55) CX75SR, CX80

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

OIL USE RANGE 1.

Mineral-based

Semi-synthetic based

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, parafn, paint solvents etc. Use only water, soap and a soft cloth. The use of petrol, parafn, paint solvents, etc, will cause discoloration, cracking or deformation of these components.

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INTRODUCTION

Hydraulic contamination ( - A.92.A.60) CX75SR, CX80

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.

When disassembling a component.

Due to normal component wear.

Due to damaged or worn seals.

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.

Control valve spools do not return to the neutral position.

Control valve spools do not move easily.

Hydraulic uid is too hot.

Hydraulic components wear quickly.

Safety valves or check valves do not close due to contamination.

Repaired components break down soon.

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:

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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 identication ( - A.80.A.10) CX75SR WE, CX80 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), make, type and serial number of the engine and serial numbers of hydraulic components.

Manufacturer’s plate

CRIL04F001E01

(1)TYPE

(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 identication ( - A.80.A.10) CX75SR NA, CX80 NA

Manufacturer’s plate

CRIL03I175E01

(1)TYPE

(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

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REPAIR MANUAL DISTRIBUTION SYSTEMS

CX75SR CX80

27084 2 14/12/2004 A

Contents DISTRIBUTION SYSTEMS - A

PRIMARY HYDRAULIC POWER SYSTEM

A.10.A

CX75SR, CX80

SECONDARY HYDRAULIC POWER SYSTEM

A.12.A

CX75SR, CX80

HYDRAULIC COMMAND SYSTEM

A.14.A

CX75SR, CX80

ELECTRICAL POWER SYSTEM

A.30.A

CX75SR, CX80

LIGHTING SYSTEM

A.40.A

CX75SR, CX80

27084 2 14/12/2004 A

DISTRIBUTION SYSTEMS - A PRIMARY HYDRAULIC POWER SYSTEM - 10.A

CX75SR CX80

27085 2 14/12/2004 A.10.A / 1

Contents DISTRIBUTION SYSTEMS - A PRIMARY HYDRAULIC POWER SYSTEM - 10.A

TECHNICAL DATA PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10)

CX75SR

PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10)

CX80

PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A - D.20.A.40)

CX75SR WE, CX80 WE

PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A - D.20.A.40)

CX75SR NA, CX80 NA

Hydraulic pump Hydraulic pump - Torque (A.10.A.20 - D.20.A.10)

CX75SR, CX80

Hydraulic pump - Special tools (A.10.A.20 - D.20.A.40)

CX75SR, CX80

Stack valve Stack valve Inlet section - Torque (A.10.A.18.10 - D.20.A.10)

CX75SR, CX80

Stack valve Outlet section - Torque (A.10.A.18.20 - D.20.A.10)

CX75SR, CX80

FUNCTIONAL DATA PRIMARY HYDRAULIC POWER SYSTEM - Static description (A.10.A - C.30.A.20)

CX75SR, CX80

PRIMARY HYDRAULIC POWER SYSTEM - Dynamic description (A.10.A - C.30.A.10)

CX75SR, CX80

Hydraulic pump Hydraulic pump - External view (A.10.A.20 - C.10.A.40)

CX75SR, CX80

Hydraulic pump - Sectional view (A.10.A.20 - C.10.A.30)

CX75SR, CX80

Stack valve Stack valve - External view (A.10.A.18 - C.10.A.40)

CX75SR

Stack valve - External view (A.10.A.18 - C.10.A.40)

CX80

Stack valve - Sectional view (A.10.A.18 - C.10.A.30)

CX75SR

Stack valve - Sectional view (A.10.A.18 - C.10.A.30)

CX80

Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30) CX75SR, CX80

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Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30)

CX75SR, CX80

Sensing system Sensing system Temperature sensor - Electronic schema (A.10.A.95.90 - C.20.A.50)

CX75SR, CX80

SERVICE PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A - F.35.A.40)

CX75SR, CX80

PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A - F.35.A.51)

CX75SR, CX80

PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)

CX75SR, CX80

PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25)

CX75SR, CX80

PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating (A.10.A - F.30.A.60)

CX75SR, CX80

Hydraulic pump Hydraulic pump - Remove (A.10.A.20 - F.10.A.10)

CX75SR, CX80

Hydraulic pump - Disassemble (A.10.A.20 - F.10.A.25)

CX75SR, CX80

Hydraulic pump - Assemble (A.10.A.20 - F.10.A.20)

CX75SR, CX80

Hydraulic pump - Install (A.10.A.20 - F.10.A.15)

CX75SR, CX80

Hydraulic pump - Bleed (A.10.A.20 - F.35.A.25)

CX75SR, CX80

Reservoir Reservoir - Remove (A.10.A.22 - F.10.A.10)

CX75SR

Reservoir - Remove (A.10.A.22 - F.10.A.10)

CX80

Reservoir - Install (A.10.A.22 - F.10.A.15)

CX75SR

Reservoir - Install (A.10.A.22 - F.10.A.15)

CX80

Oil lter Oil lter - Remove (A.10.A.24 - F.10.A.10)

CX75SR

Oil lter - Install (A.10.A.24 - F.10.A.15)

CX75SR

Stack valve Stack valve - Remove (A.10.A.18 - F.10.A.10)

CX75SR

Stack valve - Remove (A.10.A.18 - F.10.A.10)

CX80

Stack valve Inlet section - Disassemble (A.10.A.18.10 - F.10.A.25)

CX75SR, CX80

Stack valve Outlet section - Disassemble (A.10.A.18.20 - F.10.A.25)

CX75SR, CX80

Stack valve - Visual inspection (A.10.A.18 - F.40.A.10) CX75SR, CX80

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Stack valve Inlet section - Assemble (A.10.A.18.10 - F.10.A.20)

CX75SR, CX80

Stack valve Outlet section - Assemble (A.10.A.18.20 - F.10.A.20)

CX75SR, CX80

Stack valve - Install (A.10.A.18 - F.10.A.15)

CX75SR

Stack valve - Install (A.10.A.18 - F.10.A.15)

CX80

Relief valve Relief valve - Disassemble (A.10.A.16 - F.10.A.25)

CX75SR, CX80

Relief valve - Assemble (A.10.A.16 - F.10.A.20)

CX75SR, CX80

Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)

CX75SR, CX80

Sensing system Sensing system Temperature sensor - Electrical test (A.10.A.95.90 - F.40.A.50)

CX75SR, CX80

DIAGNOSTIC PRIMARY HYDRAULIC POWER SYSTEM - Troubleshooting (A.10.A - G.40.A.10)

CX75SR, CX80

Stack valve Stack valve - Troubleshooting (A.10.A.18 - G.40.A.10)

CX75SR, CX80

Relief valve Relief valve - Troubleshooting (A.10.A.16 - G.40.A.10) CX75SR, CX80

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10) CX75SR

Capacities Total hydraulic circuit Hydraulic uid reservoir Coolant only

95 L 50 L 3.5 L

Main hydraulic pump Variable ow twin pump, with axial pistons. Maximum ow Displacement

2 x 71.4 L/min 2 x 34 cm³

Hydraulic control pump Fixed ow pump Maximum ow Displacement

22,5 L/min 10.7 cm³

Secondary hydraulic pump Fixed ow pump Maximum ow Displacement

25.4 L/min 12.1 cm³

Calibration pressure Pilot circuit main relief valve (± 1 bar) Main relief valve (standard) (± 3 bar) Main relief valve (option) (± 3 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 (dozer blade) (± 5 bar) Secondary relief valve (backhoe offset) (± 5 bar) Secondary relief valve (boom and dipper) (± 5 bar)

42 bar 294 bar 226 bar 319 bar 226 bar 294 bar 255 bar 333 bar 314 bar

Boom cylinder Barrel diameter Rod diameter Stroke

110 mm 70 mm 911 mm

Dipper cylinder Barrel diameter Rod diameter Stroke

95 mm 60 mm 797 mm

Bucket cylinder Barrel diameter Rod diameter Stroke

85 mm 110 mm 665 mm

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Dozer blade cylinder Barrel diameter Rod diameter Stroke

100 mm 60 mm 180 mm

Backhoe-offset dipper cylinder Barrel diameter Rod diameter Stroke

95 mm 60 mm 685 mm

Backhoe-offset cylinder Barrel diameter Rod diameter Stroke

95 mm 55 mm 315 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)

3 mm/ 5 mn 5 mm/ 5 mn 7 mm/ 5 mn 200 mm/ 5 mn

Control valve Five-section control valve for dipper, boom acceleration, swing, option and left-side travel. Four-section control valve for dipper acceleration, bucket, boom and right-side travel. Two-section control valve for dozer blade and backhoe-offset boom. Load holding relief valve for boom and dipper. Swing motor Fixed ow motor with axial pistons. Automatic disk brake. 13.4 RPM 44.1 cm³ xxx L/min 20.6 158.3 Nm 15 bar xx 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) Acceptable motor leakage

3.4 km/h 4.9 km/h 70 % (35°) 6200 daN 32.6/21.3 cm³ 68 L/min 66.5 64.5 Nm xx L/min

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Attachment 5690 daN 3830 daN 3940 daN

Breakout force Breakout force (dipper 1,71 m) Breakout force (dipper 1,75 m - backhoe-offset)

PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10) CX80

Capacities Total hydraulic circuit Hydraulic uid reservoir Coolant only

95 L 50 L 3.5 L

Main hydraulic pump Variable ow twin pump, with axial pistons. Maximum ow Displacement

2 x 71.4 L/min 2 x 34 cm³

Hydraulic control pump Fixed ow pump Maximum ow Displacement

22.5 L/min 10.7 cm³

Secondary hydraulic pump Fixed ow pump Maximum ow Displacement

25.4 L/min 12.1 cm³

Calibration pressure Pilot circuit main relief valve (± 1 bar) Main relief valve (standard) Main relief valve blade option / option 2 (± 5 bar) Secondary relief valve (option 1) (± 5 bar) Secondary relief valve (option 2) Boom lowering secondary relief valve Dipper out port secondary relief Bucket open port secondary relief Bucket close port secondary relief Secondary relief valve (swing) (± 5 bar) Secondary relief valve (travel) (± 5 bar) Secondary relief valve (raising dozer blade) (± 5 bar) Secondary relief valve (dozer blade lowering) (± 5 bar) Secondary relief valve (RH boom offset) (± 5 bar) Secondary relief valve (LH boom offset) (± 5 bar) Safety valve (boom raising and dipper return) (± 5 bar)

42 bar 294 bar 226 bar 319 bar 255 bar 319 bar 319 bar 319 bar 319 bar 226 bar 294 bar 255 bar 255 bar 333 bar 319 bar 319 bar

Boom cylinder Barrel diameter Rod diameter Stroke

110 mm 70 mm 911 mm

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Dipper cylinder Barrel diameter Rod diameter Stroke

95 mm 60 mm 797 mm

Bucket cylinder Barrel diameter Rod diameter Stroke

85 mm 55 mm 665 mm

Dozer blade cylinder Barrel diameter Rod diameter Stroke

100 mm 60 mm 180 mm

Dipper foot offset cylinder Barrel diameter Rod diameter Stroke

95 mm 55 mm 640 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)

3 mm/ 5 mn 5 mm/ 5 mn 7 mm/ 5 mn 200 mm/ 5 mn

Control valve Five-function control valve for dipper, boom acceleration, swing (1), option and left-side travel. Four-function control valve for dipper acceleration, boom, bucket and right-side travel. Dual function control valve for dozer blade, offset and option (2). Load holding relief valve for boom and dipper. Swing motor Fixed ow motor with axial pistons. Automatic disk brakes. 13.4 RPM 44.1 cm³ xxx L/min 20.6 158.3 Nm 15 bar xx L/min

3.4 km/h 4.9 km/h 70 % (35°) 6200 daN 32.6/21.3 cm³ 68 L/min 66.5 64.5 Nm xx L/min 27085 2 14/12/2004 A.10.A / 8

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Attachment 5690 daN 3830 daN XXXX daN

Breakout force Breakout force (dipper 1.71 m) Breakout force (dipper 2.10 m)

PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A D.20.A.40) CX75SR WE, CX80 WE

Digital tester assembly

CRIL03G253E00

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

The Multi-Handy tester is used to: Check pressure (two pressure scales) Check differential pressure (delta P) Check temperature Check engine rpm Check the ï&#x20AC;&#x201A;ow

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CODE E54444449 D5444448 V5344460 W5344461 X5344462 Z5344463 E3144472 D5344467 E5344468 N5344476

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM 600 litre turbine

CRIL03G254E00

DESCRIPTION Turbine Plates M45x2 Flange diameter 24 mm Semi-ange Screw M12 length 75 mm

QUANTITY 1 2 2 4 8

CODE RE3 Z5344486 D4323359 B8230183 D4024267 Z1232983

Union assembly for testing pressure and ow

CRIL03G258E00

DESCRIPTION Union assembly for testing pressure and ow

CODE CAS30038

Set of high pressure hoses

CRIL03G259E00

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) CX75SR NA, CX80 NA

Digital tester assembly for pressure measurement

CRIL03G255E00

DESCRIPTION Digital tester assembly for pressure measurement

CODE OEM1652

Digital tester assembly for pressure and temperature measurement

CRIL03G256E00

DESCRIPTION Digital tester assembly for pressure and temperature measurement

CODE OEM1653

Flowmeter

CRIL03G257E00

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

DESCRIPTION Union assembly for testing pressure and ow

CODE CAS40023A + CAS40035

Set of high pressure hoses

CRIL03G259E00

DESCRIPTION Set of high pressure hoses

CODE CAS30036

Hydraulic pump - Torque (A.10.A.20 - D.20.A.10) CX75SR, CX80

CRIL03G048E01

(1) (2) (3) (4)

Screw Screw Safety valve Cylinder

150 - 180 Nm 55 - 69 Nm 9.8 Nm 126 - 157 Nm

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic pump - Special tools (A.10.A.20 - D.20.A.40) CX75SR, CX80

CRIL03G165E01a

Pump bracket (shaft side) Used to secure the pump in the upright position during pump removal and assembly. To be made locally. (A) Diameter 150 mm (B) Diameter 50 - 80 mm (C) 65 mm

Stack valve Inlet section - Torque (A.10.A.18.10 - D.20.A.10) CX75SR, CX80

CRIL03F160F02

(19) (28) (62) (67) (69)

Plug Plug Main relief valve Plug Plug

106-141 Nm 106-141 Nm 59-59 Nm 5.8-9.8 Nm 62-82 Nm

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Stack valve Outlet section - Torque (A.10.A.18.20 - D.20.A.10) CX75SR, CX80

CRIL03F190F01

(21) (32) (63)

Plug Plug Safety valve

61-82 Nm 106-141 Nm 59-59 Nm

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Static description (A.10.A - C.30.A.20) CX75SR, CX80

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) CX75SR, CX80

CRIL03I020G01

Controls in neutral position In neutral with the engine running, some of the ď&#x20AC;&#x201A;ow from the low pressure pump (1) is fed to (PP) and is divided by a calibrated restrictor bridge. One fraction passes through the two travel spools, and the other passes through all the other spools before rejoining the general return circuit. When the spools are moved, these circuits will be locked, which will close the upper pilot (B26) and travel pilot (B27) pressure switches. (1) Low pressure pump (2) Calibrated restrictor bridge (B26) Upper pilot pressure switch (B27) Travel pilot pressure switch

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic pump - External view (A.10.A.20 - C.10.A.40) CX75SR, CX80

CRIL03F245G01

Hydraulic pump

Secondary pump

Control pump

Cover

Main pump outlet port (A1)

Main pump outlet port (A2)

Secondary pump outlet port (A3)

Control pump outlet port (PP)

Main pump inlet port (S)

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic pump - Sectional view (A.10.A.20 - C.10.A.30) CX75SR, CX80

CRIL03F242F01

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Cover Outer spring Inner spring Cylinder block Drive shaft Swash plate Piston Retaining plate Valve plate Housing

(11) (12) (13) (14) (15) (16) (17) (18) (19)

Regulator block Control pump Secondary pump Piston Cylinder Shim Washer Piston Coupling

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Stack valve - External view (A.10.A.18 - C.10.A.40) CX75SR

CRIL03F152G01

Description (62) (63) (64) (65) (67) (69) (71)

Main relief valve Safety valve Safety valve (option) Screw Screw Plug assembly Tie rod

(72) (73) (74) (75) (78) (79) (90)

Nut Tie rod Nut Manufacturerâ&#x20AC;&#x2122;s plate Inlet plate (option) Main relief valve (option) Plug assembly

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Stack valve - External view (A.10.A.18 - C.10.A.40) CX80

CRIL04F023G01

Description (62) (63) (64) (65) (67) (69) (71)

Main relief valve Safety valve Safety valve (option) Screw Screw Plug assembly Tie rod

(72) (73) (74) (75) (78) (79) (90)

Nut Tie rod Nut Manufacturerâ&#x20AC;&#x2122;s plate Inlet plate (option) Main relief valve (option) Plug assembly

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Stack valve - Sectional view (A.10.A.18 - C.10.A.30) CX75SR

NOTE: Refer to the functions concerned for sections of the control valve block not described in this chapter.

CRIL03F163F01

Cross-section A-A (1) Control valve housing (2) LH travel spool assembly (3) Optional spool assembly (4) Swing spool assembly (5) Boom spool assembly (2) (6) Dipper spool assembly (1) (11) Large cap (12) Seal (13) Small cap (32) Plug assembly

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

CRIL03F164G01

Cross-section B-B (7) (9) (11) (13) (42) (47) (61) (78) (83)

Dipper spool assembly (2) Bucket spool assembly Large cap Small cap Seal Cap Outlet plate Optional inlet plate Backhoe-offset spool assembly

(8) (10) (12) (40) (44) (48) (62) (79) (84)

Boom spool assembly (1) Straight-line travel spool assembly Seal Spool Spring Spool Main relief valve Main relief valve (option) Dozer blade spool assembly

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Stack valve - Sectional view (A.10.A.18 - C.10.A.30) CX80

NOTE: Refer to the functions concerned for sections of the control valve block not described in this chapter.

CRIL03F163F01

Cross-section A-A (1) Timing gear case (2) LH travel spool assembly (3) Spool assembly - option (4) Spool assembly - swing (5) Spool assembly - boom (2) (6) Spool assembly - dipper (1) (11) Large cap (12) Seal (13) Small cap (32) Plug assembly

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

CRIL04F022G01

Cross-section B-B (7) (9) (11) (13) (42) (47) (61) (78) (83) (85)

Dipper spool assembly (2) Bucket spool assembly Large cap Small cap Seal Cap Outlet plate Inlet plate (option) Boom offset spool assembly Optional component assembly

(8) (10) (12) (40) (44) (48) (62) (79) (84)

Boom spool assembly (1) Straight-line travel spool assembly Seal Spool Spring Spool Main relief valve Main relief valve (option) Dozer blade spool assembly

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30) CX75SR, CX80

CRIL03F160F01

Inlet section (16) Valve (17) Spring (18) Seal (19) Plug (62) Main relief valve (69) 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) CX75SR, CX80

CRIL03F190F01

Outlet section (21) Plug assembly (32) Plug assembly (63) Safety valve

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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) CX75SR, CX80

HYDRAULIC OIL TEMPERATURE 1.

CIRCUIT CONFIGURATION

CRIL03G095E01

(1) Coolant and hydraulic oil overheating indicator lamp (2) Audible alarm device (B10) Hydraulic oil temperature thermo- switch (P1) Instrument panel 2.

TIMING DIAGRAM

CRIL03G094E02

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A F.35.A.40) CX75SR, CX80

Start the engine. The engine takes 10 to 15 minutes to warm up.

With the engine running at full speed, operate the bucket and dipper controls in one direction (against the cylinder stops) for 30 seconds.

Actuate the bucket and dipper control in the other direction (against the cylinder stops) for 30 seconds.

Repeat steps 2 and 3 until the hydraulic temperature reaches 44 - 55 °C.

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) CX75SR, CX80

IMPORTANT: This operation must be carried out before any work is done on the hydraulic circuit. 1.

Park the machine on hard, ď&#x20AC;&#x201A;at ground.

Open the bucket until the cylinder rod is completely retracted.

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. Lower the dozer blade to the ground

Reduce the engine speed to idle for 30 secondes, then shut down the engine.

Turn the starter switch key to "ON" without starting the engine.

Lower the pilot control cancellation lever.

Operate each control more than 10 times in both directions to release all pressure in the circuits.

Press the button (1) located on the hydraulic reservoir breather to release all pressure in the reservoir.

CRIL03I122A01

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A F.35.A.20) CX75SR, CX80

Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A - F.35.A.51) NOTE: It is recommended to install the vacuum pump before carrying out any work on the hydraulic circuit that requires opening the circuit. Installing this pump prevents uid loss when the circuit is opened. This chapter describes the procedure for installing the vacuum pump CAS-10193. 1.

Remove plate (A) from the top of the hydraulic reservoir. Do not remove the reservoir seal.

CRIL03I122A02

Install the adapter plate with the elbow union, refer to PRIMARY HYDRAULIC POWER SYSTEM Special tools (A.10.A - D.20.A.40).

Connect the vacuum pump to the adapter plate elbow union. Connect the vacuum pump harness to the batteries.

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) CX75SR, CX80

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)

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.

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 - Decontaminating (A.10.A - F.30.A.60) CX75SR, CX80

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.

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

CAS10508-3

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.

Replace the Ultra Clean lter, see the Operator’s Manual.

Install the valve from union kit (CAS 10508) on the reservoir drain port. Make sure that the valve is closed.

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.

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

Hydraulic pump - Remove (A.10.A.20 - F.10.A.10) CX75SR, CX80

Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20) Prior operation: Rear ballasting - Remove (F.20.B.61 - F.10.A.10) Prior operation: Silencer - Remove (B.40.A.36 - F.10.A.10) 1.

Remove the xing screws (1) and washers (2) from the silencer bracket (3), then remove the silencer bracket (3).

Mark all the hoses connected to the main pump and the control pump.

Remove and plug the inlet pipe (1) on the main pump (2). Disconnect and plug the hoses (3) and (4) on the main pump (2). Disconnect and plug the pilot hose (5) from the main pump (2). Disconnect and plug the hose (6) from the control pump (7).

CRIL03J005A01

CRIL03J005A02

CRIL03J006A01

Install a suitable lifting device with sling to support the ange and pump assembly (1). Do not allow any slack in the sling so that the lifting device supports the ange and pump assembly (1) immediately it is removed.

Remove the screws (2) and washers (3) which secure the ange and pump assembly (1) to the engine.

Gently pull the ange and pump assembly (1) horizontally away from the exible coupling secured to the engine ywheel. Set the ange and pump assembly (1) down on a clean workbench. 27085 2 14/12/2004 A.10.A / 34

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM 7.

Remove the splined sleeve (1) from the main pump shaft (2), refer to Drive system - Remove (B.90.A.42 - F.10.A.10).

CRIL03J012A01

CRIL03J011A01

CRIL03J013A01a

Remove the xing screws and washers (1), then remove the main pump, secondary pump and control pump assembly (3) and the ange (2).

Remove the secondary hydraulic pump, refer to Hydraulic pump - Remove (A.12.A.20 - F.10.A.10)

10.

Remove the splined sleeve (1) and the ring (2) connecting the main pump and the secondary pump.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic pump - Disassemble (A.10.A.20 - F.10.A.25) CX75SR, CX80

Remove the screws fastening the cover.

CRIL03F089A00

CRIL03F090A00

CRIL03F091A00

CRIL03F092A00

Remove the cover, taking care not to drop the valve plate.

Remove the outer spring, the inner spring, the guide and the spring seat.

Remove the cylinder block assembly.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM 5.

Check that the three pins have been removed from the cylinder block. Mark the position of the pistons in the cylinder block. Remove the pistons with the retaining plate.

CRIL03F093A00

CRIL03F094A00

CRIL03F095A00

CRIL03F096A00

Remove the snap ring.

Remove the seal holder and the seal.

Remove the shaft.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM 9.

Mark and remove the swash plate.

CRIL03F097A00

10.

11.

12.

Mark and remove the guide, discharge side. Mark and remove the guide, intake side.

CRIL03F098A00

CRIL03F099A00

CRIL03F100A00

Mark and remove the valve plate from the cover.

Remove the piston. Loosen and remove the cylinder.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM 13.

14.

Remove the piston, washers and shim.

CRIL03F101A00

CRIL03F102A00

CRIL03F103A00

CRIL03F104A00

Remove the screws and the ow regulator cover.

IMPORTANT: Do not remove the ow regulator unless absolutely necessary. Do not loosen the ow regulator adjustment nut, failure to comply with this instruction will alter the pressure and ow.

15.

16.

Remove the spring seat taking care not to drop the shims (if tted).

Mark and loosen the lock nut and adjustment screw, remove the spring and the spool.

IMPORTANT: Do not remove and disassemble the pilot safety valve unless absolutely necessary, failure to comply with this instruction will alter the pilot pressure.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic pump - Assemble (A.10.A.20 - F.10.A.20) CX75SR, CX80

Fit the spool and spring. Adjust the screw and tighten the nut following the marks made during removal. Tighten the pilot safety valve to the required torque.

CRIL03F105A00

CRIL03F103A00

CRIL03F102A00

CRIL03F106A01

Fit the spring seat (with the shim if tted).

Engage and tighten the ow regulator screws to the required torque.

Grease all the components lightly to keep them together. Fit the piston (1), washers (2) and shim (3) inside the cylinder (4), apply thread lock uid to the cylinder thread.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM 5.

Engage and tighten the cylinder to the required torque. Install the piston.

CRIL03F107A00

CRIL03F099A00

CRIL03F108A00

CRIL03F109A00

Grease the contact surfaces lightly to prevent the valve plate from falling. Install the valve plate.

Grease the contact surfaces lightly and ď&#x20AC; t the guide on the discharge side and the guide on the intake side.

Apply a thin coat of grease to the spherical parts in contact with the guides. Install the swash plate.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM 9.

Install the drive shaft.

CRIL03F096A00

10.

11.

12.

Install the seal.

CRIL03F110A00

CRIL03F111A00

CRIL03F094A00

Install the seal holder with its seal tted.

Install the snap ring.

27085 2 14/12/2004 A.10.A / 42

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