SM CX460 Tier3 EN PDF

Copyright
CX460 TIER 3 CRAWLER EXCAVATOR

SERVICE MANUAL
TABLE OF CONTENTS
DIVISION/SECTION
1
SECTION N
REFERENCE N
GENERAL INFORMATION
Safety, general information and standard torque data ..................................... 1001
General specifications and special torque setting ........................................... 1002
7-27691EN
SC4601002-0EN
ENGINE
Radiator and oil-cooler .................................................................................... 2001
Engine specifications ..............................................................................................*
Disassembly and assembly of the engine ..............................................................*
FUEL SYSTEM
Fuel tank .......................................................................................................... 3001
Fuel engine system ................................................................................................*
SM4603001-0EN
ELECTRICAL SYSTEM
Electrical system, electrical and electronic troubleshooting ............................ 4001
Main and engine electronic control boxes ....................................................... 4003
SC4604001-0EN
SM4604003-0EN
UNDERCARRIAGE
Removal and installation of tracks ................................................................... 5001
Rollers ............................................................................................................ 5003
Sprocket........................................................................................................... 5004
Idler wheel and tension shock absorber .......................................................... 5005
SM160B5001-0EN
SM4605003-0EN
SM160B5004-0EN
SM4605005-0EN
DRIVE TRAIN
Drive motor and final drive transmission removal and installation ................... 6001
Swing reduction gear, removal and installation ............................................... 6003
Swing reduction gear, disassembly and assembly .......................................... 6004
Travel reduction gear disassembly and assembly .......................................... 6005
SM4606001-0EN
SM4606003-0EN
SM4606004-0EN
SM4606005-0EN
UNDERCARRIAGE HYDRAULICS
UPPERSTRUCTURE HYDRAULICS
Depressurising and decontaminating the hydraulic system, use of the
vacuum pump and bleeding the components.............................................. 8000
Specifications, troubleshooting, checks and hydraulic pressure settings ........ 8001
Hydraulic reservoir removal and installation ................................................... 8002
Main and hydraulic pilot pumps, removal and installation .............................. 8003
Main hydraulic control valve, removal and installation .................................... 8004
Attachment cylinders, removal and installation ............................................... 8005
Hydraulic swivel, removal and installation ...................................................... 8006
Pilot blocs, removal and installation................................................................. 8007
Swing motor, removal and installation ............................................................. 8008
Main hydraulic pump, disassembly and assembly ........................................... 8010
Main hydraulic control valve, disassembly and assembly................................ 8011
Attachment cylinders, disassembly and assembly .......................................... 8012
Hand control levers, disassembly and assembly ............................................. 8013
Foot control levers, disassembly and assembly............................................... 8014
Six-solenoid valves, disassembly and assembly ............................................. 8015
Caution valve, disassembly and assembly ...................................................... 8016
Safety valves.................................................................................................... 8017
Hydraulic swivel, disassembly and assembly .................................................. 8018
Swing motor, disassembly and assembly ........................................................ 8019
Hydraulic functions .......................................................................................... 8020
Travel hydraulic motor, disassembly and assembly ......................................... 8021
Fan motor, removal and installation ................................................................. 8022
Fan motor, disassembly and assembly............................................................ 8023
Fan pump, removal, disassembly, assembly and installation........................... 8024
Hydraulic component functions........................................................................ 8030
CNH
SM4602001-0EN
Lep SM460TOC-0EN
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SM4608002-0EN
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SM4608015-0EN
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SC4608020-0EN
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SM4608022-0EN
SM4608023-0EN
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SC4608030-0EN
Copyright 2007 CNH France S.A.
Printed in France
September 2007
Copyright
DIVISION/SECTION
9
SECTION N
UPPERSTRUCTURE
Upperstructure, turntable and counterweight..................................................... 9002
Boom, dipper and bucket ................................................................................... 9003
Seat, removal and installation............................................................................ 9004
Cab and cab equipment..................................................................................... 9005
Air conditioning unit disassembly and assembly................................................ 9007
Large size hydraulic schematics ......................................................................Pocket
Large size electrical schematics ......................................................................Pocket
REFERENCE N
SM4609002-0EN
SM4609003-0EN
SM4609004-0EN
SM4609005-0EN
SM4609007-0EN
87574463A
87574470A
* Consult the Engine Service Manual

NOTE: CNH Company reserves the right to make changes in the specification
and design of the machine without prior notice and without incurring any obligation to modify units previously sold.
The description of the models shown in this manual has been made in accordance with the technical specifications known as of the date of design of this
document.
Lep SM460TOC-0EN
Issued 09-07
1001
Copyright
Section
1001
SAFETY, GENERAL INFORMATION
AND TORQUE SPECIFICATIONS
CNH
Lep 7-27691EN

Printed in France
February 2006
Copyright
1001-2
TABLE OF CONTENTS
GENERAL INFORMATION .......................................................................................................................................3
SAFETY..................................................................................................................................................................... 4
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6
WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see
this symbol, carefully read the message that follows, as there is a risk of serious injury.
Lep 7-27691EN
Issued 02-06
Copyright
1001-3
GENERAL INFORMATION
Cleanning
Gears
Clean all metal parts except bearings, in a suitable

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

that have wear or damage.
Inspection
Check all parts when the parts are disassembled.
Replace all parts that have wear or damage. Small
scoring or grooves can be removed with a hone or
crocus cloth. Complete a visual inspection for
indications of wear, pitting and the replacement of
parts necessary to prevent early failures.
Bearings
Check bearings for easy action. If bearings have a
loose fit or rough action replace the bearing. Wash
bearings with a suitable cleaning solvent and permit
to air dry. DO NOT DRY BEARINGS WITH
COMPRESSED AIR.
Needle bearings
Before you press needle bearings in a bore always
remove any metal protrusions in the bore or edge of
the bore. Before you press bearings into position put
petroleum jelly on the inside and outside diameter of
the bearings.
Lep 7-27691EN
Oil seals, O-rings and gaskets

Always install new oil seals, O-rings and gaskets. Put
petroleum jelly on seals and O-rings.
Shafts
Check all shafts that have wear or damage. Check
the bearing and oil seal surfaces of the shafts for
damage.
Service parts
Always install genuine Case service parts. When
ordering refer to the Parts Catalog for the correct part
number of the genuine Case replacement items.
Failures due to the use of other than genuine Case
replacement parts are not covered by warranty.
Lubrication
Only use the oils and lubricants specified in the
Operators or Service Manuals. Failures due to the
use of non-specified oils and lubricants are not
covered by warranty.
Issued 02-06
Copyright
1001-4
SAFETY
This symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED. The message that follows the
symbol contains important information about safety. Carefully
read the message. Make sure you fully understand the
causes of possible injury or death.
To prevent injury always follow the Warning, Caution

and Danger notes in this section and throughout the
manual.
Put the warning tag shown below on the key for the
keyswitch when servicing or repairing the machine.
One warning tag is supplied with each machine.
Additional tags Part Number 331-4614 are available
from your service parts supplier
WARNING: 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 operating.
It is your responsibility to understand and
f o l l o w m a n u f a c tu r e r s i n s tr u c t i o n s o n
machine operation, service and to observe
pertinent laws and regulations. Operators
and Service Manuals may be obtained from
your Case dealer.
WARNING: If you wear clothing that is too

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

fan belt with the engine running, avoid loose
clothing if possible, and use extreme caution.
WARNING: When doing checks and tests

on the equipment hydraulics, follow the
procedures as they are written. DO NOT
change the procedure.
WARNING: When putting the hydraulic

cylinders on this machine through the
necessary cycles to check operation or to
remove air from a circuit, make sure all
people are out of the way.
WARNING: Read the operators manual to

familiarize yourself with the correct control
functions.
WARNING: Operate the machine and

equipment controls from the seat position
only. Any other method could result in
serious injury.
WARNING: This is a one man machine, no

riders allowed.
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Issued 02-06
Copyright
1001-5
WARNING: When servicing or repairing the

machine, keep the shop floor and operators
compartment and steps free of oil, water,
grease, tools, etc. Use an oil absorbing
material and/or shop cloths as required. Use
safe practices at all times.
WARNING: Some components of this

machine are very heavy. Use suitable lifting
equipment or additional help as instructed in
this Service Manual.
WARNING: Engine exhaust fumes can

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

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

when working with hot parts.
WARNING: Lower all attachments to the

ground or use stands to safely support the
attachments before you do any maintenance
or service.
WARNING: Pin sized and smaller streams

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

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

remove and install pivot pins or separate
parts using compressed air or using a
grinder, wear eye protection that completely
encloses the eyes (approved goggles or
other approved eye protectors).
WARNING: Use suitable floor (service)

jacks or chain hoist to raise wheels or tracks
off the floor. Always block machine in place
with suitable safety stands.
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Issued 02-06
Copyright
1001-6
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Tightening of cap screws, nuts
Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the
order of tightening.
JS00481A
Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or
suitable cleaning solvent and dried. Apply 2-3 drops of Loctite to the thread portion of the cap screw and then
tighten.
Torque table
Tighten cap screws and nuts according to the table below if there are no other special instructions.
Cap Screw Name Size (Size)
M6
[mm]
M8
M10
M12
M14
M16
M18
M20
10
13
17
19
22
24
27
30
[in.]
0.39
0.51
0.67
0.75
0.87
0.95
1.06
1.18
[Nm]
6.9
19.6
39.2
58.8
98.1
156.9
196.1
294.2
[lb-ft]
5.1
14.5
28.9
43.4
72.3
115.7
144.6
217
[mm]
10
12
14
14
17
[in.]
0.20
0.24
0.32
0.39
0.47
0.55
0.55
0.67
[Nm]
8.8
21.6
42.1
78.5
117.7
176.5
245.2
343.2
[lb-ft]
6.5
15.9
31.1
57.9
86.9
130.2
181
253.2
Spanner
Cap Screw
Tightening
torque
Spanner
Socket
Head Cap
Screw
Lep 7-27691EN
Tightening
torque
Issued 02-06
1002
Copyright
Section
1002
SPECIFICATIONS AND SPECIAL TORQUE SETTINGS
CNH
Lep SC4601002-0EN

Printed in France
March 2007
Copyright
1002-2
TABLE OF CONTENTS
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this
symbol, carefully read the message which follows. Your safety depends on it.
TYPE, SERIAL NUMBER

AND YEAR OF MANUFACTURE OF THE MACHINE..................................................................................................... 5
Machine ....................................................................................................................................................................... 5
Engine .......................................................................................................................................................................... 5
Serial numbers of the components .............................................................................................................................. 5
FLUIDS AND LUBRICANTS ............................................................................................................................................ 6
Hydraulic fluid .............................................................................................................................................................. 6
Transmission component oil ........................................................................................................................................ 6
Grease ......................................................................................................................................................................... 6
Engine Oil .................................................................................................................................................................... 7
Engine fuel, maintenance of fuel filters and fuel storage ............................................................................................. 8
Anti-freeze/Anti-corrosion........................................................................................................................................... 10
Environment ............................................................................................................................................................... 10
Plastic and resin parts................................................................................................................................................ 10
SPECIFICATIONS ......................................................................................................................................................... 11
Main data ................................................................................................................................................................... 11
Performance .............................................................................................................................................................. 11
Complete machine dimensions .................................................................................................................................. 11
Main body dimensions ............................................................................................................................................... 11
Engine ........................................................................................................................................................................ 12
Cooling system .......................................................................................................................................................... 12
Capacity of coolant and lubricants ............................................................................................................................. 12
Hydraulic oil filter........................................................................................................................................................ 12
Fuel filter .................................................................................................................................................................... 12
Operating devices ...................................................................................................................................................... 13
Hydraulic system........................................................................................................................................................ 14
Swing unit .................................................................................................................................................................. 16
Travel lower body....................................................................................................................................................... 16
Work Unit ................................................................................................................................................................... 17
Digging force (ISO 6015) ........................................................................................................................................... 18
COMPONENT WEIGHT................................................................................................................................................. 19
Major component weight ............................................................................................................................................ 19
Bucket weight............................................................................................................................................................. 20
Other component weight ............................................................................................................................................ 21
DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY .................................................................................. 22
Sprocket ..................................................................................................................................................................... 22
Idler wheel.................................................................................................................................................................. 23
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Upper roller .................................................................................................................................................................24
Lower roller .................................................................................................................................................................25
Track...........................................................................................................................................................................26
DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS ..................................................................27
1. Boom foot/Frame ....................................................................................................................................................27
2. Boom cylinder foot/Frame.......................................................................................................................................28
3. Boom cylinder head/Boom......................................................................................................................................28
4. Arm cylinder foot/Boom ..........................................................................................................................................29
5. Boom/Arm...............................................................................................................................................................29
6. Arm cylinder head/Arm ...........................................................................................................................................29
7. Bucket cylinder foot/Arm.........................................................................................................................................30
8. Connecting rod/Arm................................................................................................................................................30
9. Compensator/Bucket ..............................................................................................................................................30
10. Connecting rod/Compensator/Bucket cylinder head ............................................................................................31
11. Arm/Bucket ...........................................................................................................................................................31
SHIMS FOR ADJUSTING ATTACHMENT GAPS ..........................................................................................................32
For boom foot .............................................................................................................................................................32
SPECIAL TORQUE SETTINGS......................................................................................................................................33
MACHINE OVERALL DIMENSIONS ..............................................................................................................................36
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1002-4
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Copyright
1002-5
TYPE, SERIAL NUMBER

AND YEAR OF MANUFACTURE OF THE MACHINE
For all part orders, request for information or assistance, always specify the type and the serial number of the machine
to your Case dealer.
Fill in the following lines with the required information: Type, serial number, year of manufacture of the machine and the
serial numbers of the hydraulic and mechanical components.
Machine
1
2
CT04A171A
(1) Type .......................................................................................................................................................................

(2) Serial number ........................................................................................................................................................
(3) Year of manufacture...............................................................................................................................................
Engine
Make and type.............................................................................................................................................................
Serial number..............................................................................................................................................................
Serial numbers of the components

Hydraulic pump ...........................................................................................................................................................
Swing reduction gear ..................................................................................................................................................
Travel reduction gears .................................................................................................................................................
Control valve ...............................................................................................................................................................
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-6
FLUIDS AND LUBRICANTS

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

Extreme pressure oil used for enclosed transmission components.
CASE/AKCELA: GEAR 135H EP (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)
Grease
CASE/AKCELA: MOLY GREASE 251H EP-M (251H EP-M. NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap and molybdenum disulphide.
CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (251H EP. NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap and calcium.
CASE/AKCELA: PREMIUM GREASE EP2 (NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap.
Hydraulic breakers
CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2).
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Issued 03-07
Copyright
1002-7
Engine Oil
THE CASE/AKCELA No. 1 engine oil is recommended
for your engine. This oil ensures proper lubrication of
your engine for all operating conditions.
If the CASE/AKCELA Multigrade "No. 1 ENGINE OIL"
cannot be obtained, use the oil corresponding to one of
the following categories: ACEA E7. API CI-4.
CP02N001
Oil viscosity / Oil range
1
2
2
3
3
CT02M001
1) With mineral base

(2) With semi-synthetic base
(3) With synthetic base
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-8
Engine fuel, maintenance of fuel filters and fuel storage

In order to meet the emission control regulation of 3rd-stage, the engine components have been made precisely and
they are to be used under high-pressure conditions.
Therefore, the specified fuel must be used for the engine.
As a matter of course, not only the guarantee will not be given for the use of a fuel other than the specified but also it
may invite a serious breakdown.
In addition, since suitable specifications for the fuel filter elements have been established for this engine, use of the genuine filter is essential.
The following describes the specifications and the requirements of the fuel to be applied, and maintenance of the fuel
and the fuel elements.
Fuel to be applied
Selection of fuel
Following conditions must be met for the diesel engines, that is the one;
1 In which no dust even fine one is mixed,
2 With proper viscosity,
3 With high cetane rating,
4 With good flow properties in lower temperature,
5 With not much sulfur content, and
6 With less content of carbon residue
Applicable standards for diesel fuel
Applicable Standard
Recommendation
JIS (Japanese Industrial Standard)
NO.2
DIN (Deutsche Industrie Normen)
DIN 51601
SAE (Society of Automotive Engineers)

Based on SAE-J-313C
NO. 2-D
BS (British Standard)
Based on BS/2869-197
Class A-1
EN590
If a standard applied to the fuel for the diesel engine is stipulated in your country, check the standard for details.
Requirements for diesel fuel
Although conditions required for the diesel fuel are illustrated above, there are other requirements exerting a big
influence on its service durability and service life.
Be sure to observe the following requirements for selecting fuel.
Sulfur content............................................................................... 2500 ppm or less
HFRR*.......................................................................................... 460 mm or less
Water content............................................................................... 0.05 wt% or less
* HFRR (High-Frequency Reciprocating Rig.): An index showing lubricating properties of the fuel.
Sulfur content reacts to moisture to change into sulfuric acid after combustion.
Use of a fuel containing much sulfur content allows it to accelerate internal corrosion and wear.
In addition, much sulfur content quickens deterioration of engine oil allowing its cleaning dispersive property to be
worse which results in acceleration of wear of sliding portions.
HFRR is an index that indicates lubricating property of a fuel.
Large value of the index means poor lubrication so that seizure of the machine components may result if such a
fuel is used.
Since a fuel with high HFRR value also has lower viscosity, it can easily be leaked out.
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-9
If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property resulting in acceleration of wear.
Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the fuel filter.
IMPORTANT : In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of condensation.
This may also cause wear and seizure of the machine components.
If atmospheric temperature goes below the freezing point, moisture content in the fuel forms fine particle of ice
allowing the fuel line to be clogged.
IMPORTANT : Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it meets the criteria described above.
IMPORTANT : If a fuel which does not meet the specifications and the requirements for the diesel engine, function and
performance of the engine will not be delivered. In addition, never use such a fuel because a breakdown of the engine
or an accident may be invited.
Guarantee will not be given to a breakdown caused by the use of a improper fuel.
Some fuels are used with engine oil or additives mixed together with diesel engine fuel.
In this case, do not use these fuels because damage to the engine may result as the fuel has been contaminated.
It is natural that the emission control regulation of 3rd-stage will not be cleared in case where a fuel that does not
meet the specifications and the requirements is used.
Use the specified fuel for compliance of the exhaust gas control.
IMPORTANT : It you use diesel fuel which contains much sulfur content more than 2500 ppm, be sure to follow the
items below for the engine oil selection and maintenance of engine parts. Guarantee will not be given to breakdowns
caused by not to follow these items.
1 Selection of engine oil
Use API grade CF-4 or JASO grade DH-1.
2 Exchange the engine oil and engine oil filter element by the periodical interval reported on the Operators
Manual.
3 Inspect and exchange the EGR (*)parts and fuel injector parts of engine every 3000 hour of use.
* EGR: Exhaust Gas Recircultion
Maintenance of fuel filters

Be sure to use the genuine fuel filters.
The fuel injection system is precisely constructed and the genuine filter employs finer mesh than conventional filters to improve protection of machine equipment.
If a filter with coarse mesh is used, foreign object passing through the filter enters into the engine so that machine
equipment can wear out in a short period of time.
IMPORTANT : If a fuel filter other than the genuine filter is used, guaranty will not be applied to a fault caused by the
use of a wrong filter.
Two kinds of fuel filter, the pre-filter and the main filter, are mounted on the machine.
Be sure to use the genuine fuel filters and replace them at the periodic intervals reported on the operators Manual.
IMPORTANT : Since the pre-filter also has a function of water separation, discharge water and sediment when the float
reaches lower part of the filter elements. CHECK EVERY DAY before to start the engine.
Time to replace filters may be advanced according to properties of the fuel being supplied.
Therefore, take measures to prevent dust or water from being entered in the fuel tank when supplying fuel.
When supplying fuel directly from a fuel drum can, leave the drum as it stands for a long period of time to supply
clean fuel standing above a precipitate.
If it is hard to leave the drum for a long period of time, install a fuel strainer and a water separator before the fuel
tank of the machine to supply clean fuel.
Water drain cock is provided on the bottom side of the fuel tank.
Drain water before starting the engine every morning.
In addition, remove the cover under the tank once a year to clean up inside of the tank.
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Copyright
1002-10
Fuel storage
Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be
traced to the presence of water in the fuel.
The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off
water and impurities regularly.
Anti-freeze/Anti-corrosion
Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.
CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710)
For areas where the temperature goes down to -38C (-36.4F), mix 50/50 with water.
IMPORTANT : Do not mix products of a different origin or brand. The same product must be used when topping up the
system.
Environment
Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants,
always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.
Contact your local ecological recycling centre or your CASE Dealer to obtain information on the correct method of disposing of these lubricants.
Plastic and resin parts

When cleaning plastic parts, the console, the instrument panel, the indicators etc... avoid using petrol, kerosene, paint
solvents etc... Use only water, soap and a soft cloth.
The use of petrol, kerosene, paint solvents etc... causes discoloration, cracks or deformation of these parts.
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Copyright
1002-11
SPECIFICATIONS
Main data
Model name ............................................................................................................................CX460 Hydraulic Excavator
Operating weight ............................................................................................................................. 46600 kg (102735 lbs)
Engine output ....................................................................................................................................... 270 kW / 1950 rpm
Performance
Swing speed....................................................................................................................................................... 9.0 Tr/min.
Travel speed
Low Speed.................................................................................................................................... 3.1 km/h (1.93 mph)
High Speed ................................................................................................................................... 5.3 km/h (3.30 mph)
Maximum drawbar pull ..........................................................................................................................341 kN (76659.85)
Grade ability ........................................................................................................................................................70% (35)
Ground pressure ............................................................................................... 80 kPa (600 mm (23.62 in) grouser shoe)
Complete machine dimensions

Standard
arm
(3.40 m)
(11 ft 1.85 in)
Short
arm
(2.55 m)
(8 ft 4.39 in)
Length
11940 mm
(470.07 in)
11990 mm
(472.04 in)
Width
3350 mm
(131.88 in)
3350 mm
(131.88 in)
Height
3600 mm
(141.73 in)
3670 mm
(144.48 in)
Main body dimensions

Main body width .............................................................................................................. See machine overall dimensions
Main body length............................................................................................................. See machine overall dimensions
Upper side swing body width ................................................................................................................. 3040 mm (120 in)
Cab width ............................................................................................................................................ 1000 mm (39.37 in)
Main body height............................................................................................................................... 3270 mm (128.73 in)
Tail swing radius ................................................................................................................................ 3620 mm (142.51 in)
Distance of rear swing body.............................................................................................................. 3600 mm (171.73 in)
Ground clearance for upperstructure ...................................................................................................... 1330 mm (52.36)
Center-to-center of wheels.................................................................................................................... 4400 mm (173.22)
Overall track length ............................................................................................................................... 5450 mm (214.56)
Maximum track width ........................................................................................................................ 3350 mm (131.88 in)
Center-to-center for track ...................................................................................................................... 2750 mm (108.26)
Width of track shoe .................................................................................600 mm (23.62 in) (Optional: 750 mm (29.52 in)
Minimum ground clearance (To bottom of lower frame) ............................................................................ 540 mm (21.25)
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-12
Engine
Name.............................................................................................................................................................ISUZU, 6UZ1
Type: ................................................................................ Water-cooled, 4-cycle diesel, 6-cylinder in line, direct injection
.............................................................(electronic control), turbocharger with air cooled intercooler, without cooling fan.
No. of cylinders - bore x stroke....................................................................................................6-dia. 120 mm x 145 mm
Displacement........................................................................................................................................ 9.839 L (2.599 gal)
Compression ratio ....................................................................................................................................................... 17.5
Rated output.......................................................................................................................................270 kW / 1950 min-1
Maximum torque................................................................................................................. 1435 Nm / apprex. 1500 min-1
Dry weight ........................................................................................................................................Approximately 840 kg
Engine dimensions (LxWxH) ........................................................................ 1235x953x1272 mm (48.62x37.51x50.07 in)
Oil pan ...................................................................................................................................... All direction 35, inclinable
Cooling fan ................................................... Remote (diameter 1016 mm (39.99 in) suction type-6 blades resin & steel)
Oil pan capacity.................................................. Maximum: 36 L (9.51 gal) Minimum: 25 L (6.60 gal) (excluding oil filter)
Direction of rotation ...................................................................................................................... Right (as seen from fan)
Starter, reduction type ................................................................................................................................... .24 V, 5.5 kW
Alternator, AC type ............................................................................................................................................. 24 V, 50 A
Battery ............................................................................................................................................... 2 x 12V, 128 Ah/5 Hr
Cooling system
Fan drive system .........................................................................................................................................Hydraulic drive
Fan type........................................................................................................... 1016 mm (39.99 in), 6 blades, air intake
Radiator
Fin type .................................................................................................................................................................. wavy
Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in)
Oil cooler
Fin type .................................................................................................................................................................. wavy
Fin pitch ........................................................................................................................................... 1.75 mm (0.069 in)
Inter-cooler
Fin type ...............................................................................................................................................triangular straight
Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in)
Fuel cooler
Fin type .................................................................................................................................................................. wavy
Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in)
Capacity of coolant and lubricants

Coolant ...................................................................................................................................................... 38 L (10.03 gal)
Fuel ....................................................................................................................................................... 611 L (161.41 gal)
Lubricant for engine..................................................................................................................................... 36 L (9.51 gal)
Lubricant for travel reduction gear (per side)............................................................................................... 15 L (3.96 gal)
Lubricant for swing reduction gear (per side) ........................................................................................... 10.5 L (2.77 gal)
Hydraulic oil........................................................................................................................................... 460 L (121.51 gal)
Capacity of hydraulic oil tank................................................................................................................... 230 L (60.76 gal)
Hydraulic oil filter

Suction filter (inside tank) ....................................................................................................................................150 mesh
Return filter (inside tank) .......................................................................................................................................... 10 m
Nephron filter (inside housing) ................................................................................................................................... 1 m
Pilot line filter (inside housing).................................................................................................................................. 10 m
Fuel filter
Main filter.................................................................................................................................................................... 4 m
Pre-filter.................................................................................................................................................................... 10 m
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-13
Operating devices
Operator's seat
Location: left side
Structure: KAB 555: Low frequency air suspension with helical springs and double acting hydraulic damper.
Cab
Smooth and round shape design cab, fabricated by press work Safety glass for all window.
Levers and pedals
For travel use: Levers and pedals (hydraulic pilot type) (x2)
For operating machine use: Levers (hydraulic pilot type) (x2)
Instruments and switches
Work mode switchover: 4 modes (heavy digging, standard, finishing and auto)
Travel speed switchover: Low-speed / high-speed switch
One-touch idle: Knob switch type
Monitor device
Machine status display (full-dot liquid crystal)
Travel speed selection status: Low Speed / High Speed
Work mode selection status: H/S/L/A
Auto idle selection status: ON/OFF
Instruments (full-dot liquid crystal, except for hour meter)
Fuel gauge: bar graph indicator
Engine coolant temperature gauge: bar graph indicator
Hydraulic oil temperature gauge: bar graph indicator
Hour meter: digital type
Machine Status and Warning Alarms (full-dot liquid crystal and warning tone) *Items have a warning alarm
Over heat*
Battery charge*
Faulty electrical system*
Refill fuel*
Engine oil pressure*
Refill coolant*
Engine preheat
Auto warm-up
Air cleaner
Idling
Service interval
Digging power up
Lighting
Working light
House:
24V, 70W (x1)
Boom:
24V, 70W (x1)
Cab:
24V, 70W (x2)
Interior light
24V, 10W (x1)
Horn: electric horn (x2)

Other:
Wiper with intermittent function.
Window washer fluid.
Air conditioner.
Rear view mirror (left and right side).
DC-DC converter.
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-14
Hydraulic system
Hydraulic pump drive system, directly coupled to the engine (no transmission)
Main pump
Manufacturer............................................................................................................................................... Kawasaki
Pump type .............................................................................................. double variable displacement piston pump
Displacement volume ................................................................................................. 182 cm3 (11.11 cu in) x 2 /rev
Rated operating pressure .......................................................................................................... 31.4 MPa (4554 psi)
Maximum operating pressure .................................................................................................... 34.3 MPa (4975 psi)
Input revolution speed......................................................................................................1980 min-1 (at 1980 rpm-1)
Maximum discharge flow .................................................. 360 L/min (95.10 gpm) x 2 at 1980 min-1 (at 1980 rpm-1)
Input horsepower ........................................................................................................................................ 221.6 kW
Shaft input horsepower ................................................................................224.7 kW at 1980 min-1 (at 1980 rpm-1)
Shaft input torque .............................................................................................. 1072.8 Nm (791 lb-ft) at 1980 min-1
Pilot pump
Pump type ............................................................................................................................................... Gear pump
Displacement volume ............................................................................................................ 15 cm3 (0.91 cu in)/rev
Operating pressure ........................................................................................................................ 3.9 MPa (566 psi)
Maximum flow ....................................................................... 29.7 L/min (7.84 gpm) (at 1980 min-1) (at 1980 rpm-1)
Input horsepower ............................................................................................................................................ 3.1 kW
Control characteristics
Simultaneous output control of overall.
Negative control.
Electric horse power control.
Control Valve
Model; 4-spool section: integrated (1) or 5-spool section: integrated (1)
Operation method: hydraulic pilot method: travel, swing and operating machine
Maximum flow .......................................................................................................................... 360 L / min (95.10 gpm)
Main relief set pressure.......................................................standard; 31.4 MPa (4554 psi) (at 340 L/min (89.81 gpm))
...................................................................................... power boost; 34.3 MPa (4975 psi) (at 315 L/min (83.21 gpm))
Overload set pressure.............................................. when boom down; 24.5 MPa (3553 psi) (at 20 L/min (5.28 gpm))
..................................................................................................... other: 36.3 MPa (5265 psi) (at 20 L/min (5.28 gpm))
Foot relief set pressure ......................................................................3.38 MPa (490.22 psi) (at 61 L/min (16.11 gpm))
Functions
Straight travel circuit
Boom up / 2-speed internal confluence for arm
Boom/Arm load holding circuit
Boom down regenerative circuit
Arm in forced regenerative circuit
Boom up override variable throttle valve
Swing priority variable throttle valve
Backup 2-speed confluence
Hydraulic Cylinders
Boom cylinder (x2)
Cylinder bore .............................................................................................................................170 mm (6.69 in)
Rod diametre .............................................................................................................................115 mm (4.52 in)
Maximum retracted length .......................................................................................................... 2230 mm (87.79 in)
Stroke ......................................................................................................................................... 1550 mm (61.02 in)
Arm (dipper) cylinder
Maximum retracted length ........................................................................................................ 2588 mm (101.88 in)
Stroke ......................................................................................................................................... 1820 mm (71.65 in)
Bucket cylinder
Maximum retracted length .......................................................................................................... 1972 mm (77.63 in)
Stroke ......................................................................................................................................... 1285 mm (50.59 in)
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-15
Rotating Joint
Operating pressure
High pressure passage (ABCD) ............................................................................................... 34.3 MPa (4975 psi)
Drain port (T) ................................................................................................................................. 1.0 MPa (145 psi)
Pilot port (P) .................................................................................................................................. 3.9 MPa (566 psi)
Hydrostatic test pressure
High pressure passage (ABCD) ................................................................................................ 51.5 MPa (7469 psi)
Drain port (T) ................................................................................................................................. 2.0 MPa (290 psi)
Pilot port (P) .................................................................................................................................. 5.9 MPa (856 psi)
Flow
High pressure passage (ABCD) .......................................................................................... 360 L / min (95.10 gpm)
Drain port (T) ......................................................................................................................... 40 L / min (10.56 gpm)
Pilot port (P) ............................................................................................................................ 31 L / min (8.18 gpm)
Number of revolutions...................................................................................................................... 15 min-1 (15 rpm-1)
Torque; when pressurizing 2 ports..................................................................................................196 Nm (144.5 lb-ft)
Port A; forward right ...................................................................................................................................................G1
Port B; forward left .....................................................................................................................................................G1
Port C; backward right ...............................................................................................................................................G1
Port D; backward left..................................................................................................................................................G1
Port E; drain port ....................................................................................................................................................G1/2
Port F; pilot port ..................................................................................................................................................... G1/4
Solenoid Valve
Valve specifications
Maximum flow...................................................................... P -> B: 20 L/min (5.28 gpm) Other: 5 L/min (1.32 gpm)
Rated pressure ......................................................................................................................... 4.5 MPa (652.67 psi)
Solenoid specifications
Operating voltage ................................................................................................................................ DC 20 to 32 V
Power consumption .................................................................................................................................. 17 W max.
Hand control valve
Manufacturer................................................................................................................................................... Kawasaki
Operating pressure .......................................................................................................................... 3.92 MPa (569 psi)
Secondary pressure, primary short type .......................................................... 0.49 to 2.89 MPa (71.06 to 419.15 psi)
Operating angle
Ports 1, 3 .............................................................................................................................................................. 19
Ports 2, 4 .............................................................................................................................................................. 25
Operating torque
Port 1 ...................................................................................................................0.58 to 2.03 Nm (0.42 to 1.49 lb-ft)
Port 3 ...................................................................................................................0.47 to 1.92 Nm (0.34 to 1.41 lb-ft)
Ports 2, 4 .............................................................................................................0.71.to 2.30 Nm (0.52 to 1.69 lb-ft)
Foot control valve
Manufacturer................................................................................................................................................... Kawasaki
Operating pressure .......................................................................................................................... 3.92 MPa (569 psi)
Secondary pressure, primary short type .......................................................... 0.49 to 2.89 MPa (71.06 to 419.15 psi)
Operating angle ..................................................................................................................................................... 12.4
Operating torque
Valve................................................................................................................. 4.16 to 9.03 Nm (3.068 to 6.660 psi)
Damper.........................................................................................4.90 Nm (at 0.0275 m/s) (3.614 psi (at 0.090 f/s))
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-16
Swing unit
Swing circle ......................................................................................................... Swing bearing type (with internal gears)
Swing parking brake ................................................................................ Mechanical lock (operational lever linkage type)
Swing lock .............................................................................................. Mechanical lock (swing lock switch linkage type)
Swing hydraulic motor .....................................................................................................Fixed displacement piston motor
Displacement ......................................................................................................................... 250 cm3 (15.26 cu in)/rev
Operating pressure ........................................................................................................................ 29.4 MPa (4264 psi)
Operating flow ............................................................................................................................. 360 L/min(95.10 gpm)
Mechanical brake torque.....................................................................................................1288 Nm (949.97 lb-ft) min.
Brake off pressure................................................................................................................ 2.9 MPa (420.60 psi) max.
Relief valve set pressure....................................................................................................... 29.3 MPa (4249 psi) max.
Reduction gear .................................................................................................. Planetary gear 2-stage reduction System
Reduction ratio ........................................................................................................................................................ 27.143
Travel lower body

Travel hydraulic motor (x2) ......... Variable displacement piston motor, automatic 2-speed switch-over with parking brake
Displacement .............................................................................................. 290.7/170.1 cm3 (17.74/10.38 cu in)/rev
Operating pressure .................................................................................................................... 34.3 MPa (5192 psi)
Operating flow..................................................................................................................... 360.4 L/min (95.20 gpm)
Brake torque................................................................................ 71 KNm (52366 Ib-ft) min. (including reduction gear)
Relief valve set pressure ............................................35.8 to 38.8 MPa (at 50L/min) (5192 to 5627 psi (at 13.20 gpm)
Automatic 2-speed switch-over pressure ....................................................................................... 26.5 MPa (3843 psi)
Reduction gear ...................................................................................................Planetary gear 3-stage reduction system
Reduction ratio .................................................................................................................................................... 60.652
Travel brake .................................................................................................................................................. Hydraulic lock
Parking brake ................................................................................................... Mechanical lock (travel lever linkage type)
Track shoe
Model ....................................................................................................................... Assembly-type triple grouser shoe
Number of shoes (per side)........................................................................................................................................ 50
Shoe width
Standard ....................................................................................................................................... 600 mm (23.62 in)
Optional ....................................................................................................................................... 750 mm (29.52 in)
Grouser height ...................................................................................................................................... 36 mm (1.41 in)
Link pitch .......................................................................................................................................... 228.6 mm (8.99 in)
Roller
Number of upper rollers (per side) ............................................................................................................................... 2
Number of lower rollers (per side)................................................................................................................................ 9
Track belt tension adjuster............................................................................... Grease cylinder type (with cushion spring)
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-17
Work Unit
Model ................................................................................................................................................. Backhoe attachment
Capacity / dimensions / working dimensions
Bucket width.................................................................................................... 1400 mm (55.11 in) (without side cutter)
Width of bucket with side cutter ....................................................................................................... 1510 mm (5944 in)
Weight of bucket with side cutter ......................................................................................................1830 kg (4034 lbs)
Boom
6980 mm
(274.80 in)
Arm (dipper) length
Standard arm
Short arm
3380 mm
(133.07 in)
2530 mm
(99.60 in)
1840 mm
72.44 in
Bucket radius
Bucket wrist angle
176
Maximum digging radius
12000 mm
472.43 in
11230 mm
442.12 in
Maximum digging radius at ground line
11770 mm
463.38 in
10990 mm
432.67 in
Maximum digging depth
7720 mm
303.93 in
6870 mm
270.47 in
Maximum vertical straight wall digging depth
6570 mm
258.66 in
5670 mm
223.22 in
Maximum reach height
11140 mm
438.58 in
10820 mm
425.98 in
Maximum dump height
7740 mm
304.72 in
7420 mm
292.12 in
Minimum swing radius at front
4990 mm
196.45 in
5140 mm
202.36 in
Overall height with minimum swing radius at front
9250 mm
364.17 in
9320 mm
366.92 in
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-18
Digging force (ISO 6015)

Arm (dipper)
3380 mm
(133.07 in)
2530 mm
(99.60 in)
Bucket digging force (standard)
247 kN
(55527.8 lbf)
247 kN
(55527.8 lbf)
Bucket digging force (power boost)
270 kN
(60698.4 lbf)
270 KN
(60698.4 lbf)
209 kN
(46985 lbf)
257 kN
(57775.9 lbf)
229 kN
(51481.2 lbf)
281 kN
(63171.3 lbf)
Arm (dipper) digging force (standard)

Arm (dipper) digging force (power boost)
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-19
COMPONENT WEIGHT
Major component weight
B
A
C
G
H
330.3.01.00.51A
Weight information is approximate

A) Operating weight .................................................................................................................... 46600 kg (102735 lbs)
B) Upper mechanism (including counterweight and turntable bearing) ........................................ 19700 kg (43431 lbs)
C) Counterweight............................................................................................................................ 9200 kg (20282 lbs)
D) Lower mechanism (with standard grouser shoe) .....................................................................16700 kg (36817 lbs)
E) Main Unit Weighty ....................................................................................................................36400 kg (80248 lbs)
F) Attachments .............................................................................................................................10000 kg (22046 lbs)
G) Boom (including cylinders)......................................................................................................... 5540 kg (12213 lbs)
H) Arm (dipper) (including cylinders and linkage).............................................................................2670 kg (5886 lbs)
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-20
Bucket weight
Bucket capacity (m3)
Weight kg (lbs)
L1 mm (in)
L2 mm (in)
1.8
1430 (3153)
1384 (54.48)
1515 (59.64)
1.8 HD
1810 (3990)
1400 (55.11)
1508 (59.36)
2.0
1500 (3307)
1514 (59.60)
1645 (64.76)
2.0 HD
1910 (4211)
1530 (60.23)
1638 (64.48)
2.2
1510 (3329)
1825 (71.85)
1956 (77.00)
L1
L2
330.3.01.00.51BA
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-21
Other component weight

Engine .....................................................................................................................................................840 kg (1852 lbs)
Air cleaner ...............................................................................................................................................17.6 kg (38.8 lbs)
Hydraulic pump ......................................................................................................................................... 245 kg (540 lbs)
Attachment control valve ........................................................................................................................... 424 kg (935 lbs)
Swing motor (excluding pinion) ...............................................................................................................565 kg (1245 lbs)
Travel motor and reduction gear assembly .............................................................................................613 kg (1351 lbs)
Rotary joint..................................................................................................................................................56 kg (123 lbs)
Solenoid valve bank .................................................................................................................................. 7.0 kg (15.4 lbs)
Hand control valve ......................................................................................................................................1.9 kg (4.2 lbs)
Foot control valve ...................................................................................................................................... 7.8 kg (17.2 lbs)
Standard boom......................................................................................................................................3540 kg (7804 lbs)
Standard arm (dipper)...........................................................................................................................1690 kg (3726 lbs)
Short arm (dipper).................................................................................................................................1490 kg (3285 lbs)
Boom cylinder (one) .................................................................................................................................. 400 kg (882 lbs)
Arm (dipper) cylinder...............................................................................................................................695 kg (1532 lbs)
Bucket cylinder .......................................................................................................................................... 390 kg (860 lbs)
Fuel tank ................................................................................................................................................... 243 kg (536 lbs)
Hydraulic oil tank....................................................................................................................................... 229 kg (505 lbs)
Turntable bearing ....................................................................................................................................656 kg (1446 lbs)
Muffler ........................................................................................................................................................... 20 kg (44 lbs)
Radiator total weight ................................................................................................................................. 208 kg (458 lbs)
Oil cooler................................................................................................................................................... 34 kg (75 lbs)
Radiator ..............................................................................................................................................23.3 kg (51.3 lbs)
Air cooler................................................................................................................................................ 28.8 kg (63 lbs)
Fuel cooler ............................................................................................................................................ 1.2 kg (2.64 lbs)
Idler wheel................................................................................................................................................. 251 kg (553 lbs)
Upper roller ................................................................................................................................................... 44 kg (97 lbs)
Lower roller .................................................................................................................................................82 kg (181 lbs)
Recoil spring ............................................................................................................................................. 343 kg (756 lbs)
Recoil spring ...................................................................................................................................... 141 kg (310.8 lbs)
Grease cylinder assembly ................................................................................................................ 62.3 kg (137.3 lbs)
Threaded ..........................................................................................................................................68.8 kg (151.6 lbs)
Yoke ..................................................................................................................................................66.8 kg (147.2 lbs)
Track chains (per side)
600 mm (23.62 in).............................................................................................................................2580 kg (5688 lbs)
750 mm (29.52 in).............................................................................................................................2930 kg (6459 lbs)
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-22
DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY

Sprocket
Dimensions
P
800.6.10.00.11A1
Dimension
Mark
a
b
c
d
e
P
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
mm
in
90
78
773.6
761.6
867.5
854.5
847.3
43.5
48.5
229
-
3.54
3.07
30.45
29.98
34.15
33.64
33.35
1.71
1.90
9.01
-
Gauge
Unit in mm
300
228.6
44.8
5.4
3 .1
117.8
99.6
37.9
R
3
6
R
95
.6
R
36
.9
R
50
.7
24.5
90
40.2
87.6
7
23.
R4
.8
33
R4
CI01N501
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-23
Idler wheel
Dimensions
c
Dimension
mm
in
Mark
Standard
Limit
Standard
b
Limit
Standard
c
Limit
Standard
d (shaft)
Limit
Standard
d (bushing)
Limit
Standard
e (bushing)
Limit
Standard
f
Limit
676
665
22.5
102
92
95
94
95
96
100
99
15
-
e
d
26.61
26.18
0.88
1.00
4.01
3.62
3.74
3.70
3.74
3.77
3.93
3.89
0.59
-
330.6.10.00.12B
Gauge
Unit in mm
250
204
22.5
15
R3
R5
R50
R3
10
80
42.5
102
0.2
CI01N502
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-24
Upper roller
Dimensions
c
Dimension
mm
in
Mark
Standard
Limit
Standard
b
Limit
Standard
c
Limit
Standard
d shaft
Limit
Standard
d bushing
Limit
Standard
e bushing
Limit
Standard
f
Limit
Standard
g
Limit
150
140
15
104
65
64
65
66
150
149
9
8.5
30
-
e
f
000.6.10.00.8C
5.90
5.51
0.59
4.09
2.55
2.51
2.55
2.59
5.90
5.86
0.35
0.33
1.18
-
Gauge
Unit in mm
210
104
97
R3
R3
R3
15
65
35
.1
13
R3
15
R3
125
120
245
CI01N503
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-25
Lower roller
Dimensions
d
000.6.10.00.08D
Dimension
mm
in
Mark
a
b
d
e (Shaft)
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
200
188
25
20
223
233
85
84
7.87
7.40
0.98
0.78
8.77
9.17
3.34
3.30
Dimension
mm
in
Mark
e (bushing)
f
g
Standard
Limit
Standard
Limit
Standard
Limit
85
86
93
92
24.5
23.9
3.34
3.38
3.66
3.62
0.96
0.94
Gauge
Unit in mm
KTA1107X-C02
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-26
Track
c
d
f (4 pieces)
a
800-6-10-00-11E-1
Mark
Standard
Limit
Standard
b
Limit
Standard
c (bushing)
Limit
Standard
d (bushing)
Limit
Standard
e (Pin)
Limit
Standard
f
Limit
Lep SC4601002-0EN
Dimension
mm
in
52
32
129
121
73.33
68.23
49.2
51.7
48.6
45.1
228.6
-
2.04
1.25
5.07
4.76
2.88
2.68
1.93
2.03
1.91
1.77
8.99
-
Mark
Standard
Limit
Standard
d (bushing)
Limit
Standard
e (Pin)
Limit
Standard
f (4 pieces)
Limit
c (bushing)
Dimension
mm
in
73.33
68.23
49.2
51.7
48.8
44.9
914.4
-
2.88
2.68
1.93
2.03
1.92
1.76
35.99
-
Issued 03-07
Copyright
1002-27
DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS

4
6
7
1
10
9
3
5
2
8
11
CRIL06C002F
1. Boom foot/Frame
a
b
330.6.10.00.12C1
Dimension
mm
in
Mark
a (frame)
b (boom)
c (clearance)
d (shaft)
e (bushing)
Lep SC4601002-0EN
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
874
34.40
882
34.72
871
34.29
868
34.17
3.5 to 5.5
0.13 to 0.21
Shim adjustment
120
4.72
119
4.68
120
4.72
121.5
4.78
Issued 03-07
Copyright
1002-28
2. Boom cylinder foot/Frame

a
b
330.6.10.00.1.12C2
Dimension
mm
in
Mark
a (boom)
b (cylinder)
c (clearance)
d (shaft)
e (bushing)
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
126
4.96
132
5.19
125
4.92
122
4.80
1.5 to 3.5
0.05 to 0.13
Shim adjustment
120
4.72
119
4.68
120
4.72
121.5
4.78
3. Boom cylinder head/Boom

a
c
330.6.10.00.12D1
Dimension
Mark
a (boom)
a (cylinder)
c (clearance)
d (shaft)
d (bushing)
Lep SC4601002-0EN
mm
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
in
140
5.51
137
5.39
679
26.73
675
26.57
1.5 to 3.0
0.05 to 0.11
Shim adjustment
120
4.72
119
4.68
120
4.72
121.5
4.78
Issued 03-07
Copyright
1002-29
4. Arm cylinder foot/Boom

a
Mark
Standard
Limit
Standard
b (cylinder)
Limit
Standard
c (clearance)
Limit
Standard
d (shaft)
Limit
Standard
e (bushing)
Limit
a (boom)
Dimension
mm
in
156
6.14
162
6.37
155
6.10
153
6.02
1.0 to 3.0
0.03 to 0.11
Shim adjustment
120
4.72
119
4.68
120
4.72
121.5
4.78
330.6.10.00.12D2
5. Boom/Arm
g
a
b
Mark
330.6.10.00.12E1
Standard
Limit
Standard
b (arm)
Limit
Standard
c (clearance)
Limit
Standard
d (shaft)
Limit
Standard
e (bushing)
Limit
Standard
g
Limit
a (boom)
Dimension
mm
in
437
17.20
440
17.32
432.7
17.03
429.7
16.91
4.5 to 5.5
0.17 to 0.21
Shim adjustment
120
4.72
119
4.68
120
4.72
121.5
4.78
98
3.85
96
3.77
6. Arm cylinder head/Arm

a
b
Mark
Standard
Limit
Standard
b (cylinder)
Limit
Standard
c (clearance)
Limit
Standard
d (shaft)
Limit
Standard
e (bushing)
Limit
a (arm)
Dimension
mm
in
156
6.14
161
6.33
155
6.10
153
6.02
1.0 to 3.0 0.039 to 0.11
Shim adjustment
120
4.72
119
4.68
120
4.72
121.5
4.78
330.6.10.00.12F1
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-30
7. Bucket cylinder foot/Arm

a
Mark
Standard
Limit
Standard
b (cylinder)
Limit
Standard
c (clearance)
Limit
Standard
d (shaft)
Limit
Standard
e (bushing)
Limit
a (arm)
330.6.10.00.12F2
Dimension
mm
in
141
5.55
146
5.74
140
5.51
138
5.43
1.0 to 3.0
0.039 to 0.11
Shim adjustment
110
4.33
109
4.29
110
4.33
111.5
4.38
8. Connecting rod/Arm
c
Mark
Standard
Limit
Standard
b
Limit
Standard
c (clearance)
Limit
Standard
d (shaft)
Limit
Standard
e (bushing)
Limit
e
a
d
Dimension
mm
in
50
1.96
47
1.85
441
17.36
437
17.20
1.5 to 2.0
0.059 to 0.078
Shim adjustment
95
3.74
94
3.70
95
3.74
96.5
3.79
330.6.10.00.12G1
9. Compensator/Bucket
c
Mark
Standard
Limit
Standard
b (link)
Limit
Standard
c (clearance)
Limit
Standard
d (shaft)
Limit
Standard
e (bushing)
Limit
a (bucket)
b a
e
Dimension
mm
in
480
18.89
485
19.09
479
18.85
476
18.74
1.5 to 3.5
0.059 to 0.13
Shim adjustment
100
3.93
99
3.89
100
3.93
101.5
3.99
330.6.10.00.12G2
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-31
10. Connecting rod/Compensator/Bucket cylinder head

c
Mark
a
f
d e
Standard
Limit
Standard
b
Limit
Standard
c (clearance)
Limit
Standard
d (link)
Limit
Standard
e (cylinder)
Limit
Standard
f (clearance)
Limit
Standard
g (shaft)
Limit
Standard
h (bushing)
Limit
Standard
i (bushing)
Limit
h
a
g
330.6.10.00.12H1
Dimension
mm
in
50
1.96
48
1.88
441
17.36
436
17.16
1.5 to 2.5
0.059 to 0.098
Shim adjustment
141
5.55
143
5.62
140
5.51
138
5.43
1.5 to 2.0
0.059 to 0.078
Shim adjustment
110
4.33
109
4.29
110
4.33
111.5
4.38
110
4.33
111.5
4.38
11. Arm/Bucket
c
d
Mark
g
Standard
Limit
Standard
b (arm)
Limit
Standard
c (clearance)
Limit
Standard
d
Limit
Standard
e (shaft)
Limit
Standard
f (bushing)
Limit
Standard
g (bushing)
Limit
a (bucket)
f
a b
Dimension
mm
in
480
18.89
479
18.85
476
18.74
1.5 to 4.0
0.059 to 0.15
Shim adjustment
16
0.62
10
0.39
100
3.93
99
3.89
100
3.93
101.5
3.99
100
3.93
101.5
3.99
330.6.10.00.12I1
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-32
SHIMS FOR ADJUSTING ATTACHMENT GAPS

For boom foot
R
O.D I.D
000-6-10-02-02A
Part No.
I.D.
O.D.
Shim
Thickness
Material
KNV1132
76
160
100
30
1.2
SPHC
KRV2390
91
190
115
30
1.2
SPHC
KBV1441
101
220
130
30
1.2
SPHC
KBV1748
101
230
135
30
1.2
SPHC
KSV1805
111
240
140
30
1.2
SPHC
R
O.D
I.D
000-6-10-02-02B
Part No.
I.D.
O.D.
Shim
Thickness
Material
KSV1930
111
240
140
30
1.0
Urethone
KSV11380
111
240
140
30
2.0
Urethone
KSV1931
116
240
140
30
1.0
Urethone
KSV11390
116
240
140
30
2.0
Urethone
KTV10730
121
245
150
50
2.0
Urethone
KTV10740
121
245
150
50
1.0
Urethone
KTV10750
121
260
150
50
2.0
Urethone
KTV10760
121
260
150
50
1.0
Urethone
KWV0097
141
280
160
50
1.0
Urethone
KWV10510
141
280
160
50
2.0
Urethone
KWV0096
141
300
180
50
1.0
Urethone
KWV10500
141
300
180
50
2.0
Urethone
KUV10150
141
300
170
30
1.0
Urethone
KUV10160
141
300
170
30
2.0
Urethone
KUV10130
151
300
170
30
1.0
Urethone
KUV10140
151
300
170
30
2.0
Urethone
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-33
SPECIAL TORQUE SETTINGS

No.
1*
Component
Travel motor and reduction gear assembly
Screw
Wrench (mm)
M24
36
Torque setting
900-1052 Nm (664-776 lb-ft)
2*
Drive sprocket
M24
36
900-1052 Nm (664-776 lb-ft)
3*
Take-up Roller
M16
24
267-312 Nm (197-230 lb-ft)
4*
Upper roller
M24
36
521-608 Nm (385-448 lb-ft)
5*
Lower roller
M24
36
902-1049 Nm (665-774 lb-ft)
6*
Track guard
M24
36
902-1049 Nm (665-774 lb-ft)
Shoe bolt
M24
32
1236-1510 Nm (912-1114 lb-ft)
Counterweight
M30
46
1765-2010 Nm (1302-1482 lb-ft)
9*
Turntable bearing
M24
36
952-1050 Nm (702-774 lb-ft)
10 *
Swing equipement
11 *
12 *
Engine
13 *
14 *
M24
36
900-1050 Nm (664-774 lb-ft)
Mount
M20
30
324-373 Nm (239-275 lb-ft)
Front bracket
M10
17
64-73 Nm (47-54 lb-ft)
Rear bracket
M16
24
147-176 Nm (108-130 lb-ft)
Radiator
M16
24
147-176 Nm (108-130 lb-ft)
Frange
M12
19
88-108 Nm (65-79 lb-ft)
Pump
M20
17
367-496 Nm (271-366 lb-ft)
15 *
16 *
Hydraulic pump
17 *
Hydraulic reservoir
M16
24
226-265 Nm (167-195 lb-ft)
18 *
Fuel reservoir
M16
24
226-265 Nm (167-195 lb-ft)
19 *
Control valve
M20
30
333-392 Nm (245-289 lb-ft)
Lock bar
M16
24
267-312 Nm (197-230 lb-ft)
Joint
M12
19
54-64 Nm (40-47 lb-ft)
20 *
21 *
22
23 *
24
Rotating joint
Cab
Battery
Floor
M16
24
78-80 Nm (57-59 lb-ft)
Mount
M10
17
35-42 Nm (26-31 lb-ft)
M10
17
20-29 Nm (15-21 lb-ft)
NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-34
19
15, 16
17
11, 12, 13
10
18
14
24
7
20, 21
1, 2
9
5
22, 23
4
7
4
5
TORQUE_1
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-35
10
15
14
12
11
16
13
19
18
17
20
22
24
21
23
TORQUE_2
Lep SC4601002-0EN
Issued 03-07
Copyright
1002-36
MACHINE OVERALL DIMENSIONS

NOTE: Numbers are subject to change without notice due to design change or other reasons.
The figures give values that include the shoe lug height (36 mm (1.41 in))
Standard arm (3380 mm (133.07 in))

* : with catwalks - (option)
*
BKTU6001_338M
Short arm (2530 mm (99.60 in))

* : with catwalks - (option)
*
BKTU6001_253M
Lep SC4601002-0EN
Issued 03-07
2001
Copyright
Section
2001
FUEL-COOLER, ENGINE INTER-COOLER,
RADIATOR AND OIL-COOLER
CNH
Lep SM4602001-0EN

Printed in France
September 2007
Copyright
2001-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
RADIATOR, OIL-COOLER, INTER COOLER AND FUEL COOLER ............................................................................. 3
Removal ..................................................................................................................................................................... 3
Installation .................................................................................................................................................................. 3
ENGINE .......................................................................................................................................................................... 4
Removal ..................................................................................................................................................................... 4
Installation .................................................................................................................................................................. 4
ENGINE AND RADIATOR - FIGURE 1 .......................................................................................................................... 6
SPECIFICATIONS
See Section 1002
Lep SM4602001-0EN
Issued 09-07
Copyright
2001-3
RADIATOR, OIL-COOLER, INTER COOLER AND FUEL COOLER

Before carrying out any operation on the machine, perform the following operations in the order shown:
-
Park the machine on hard, flat ground.

Lower the attachment to the ground.
Shut down the engine.
Remove the starter switch key.
Make sure that pressure in the hydraulic system has been completely released (see Operators Manual).
WARNING: When the machine is working, the engine components and the hydraulic pump reach a high temperature. To avoid being burnt by hot metal or scalded by high temperature water or oil, allow the machine to cool
down before starting any servicing operation.
Removal
Installation
NOTE: For the removal refer to the figure 1, page 6.
NOTE: For the installation refer to the figure 1, page 6,

proceed in the reverse order from that of removal.
STEP 1
Drain the cooling system (see Operators Manual).
STEP 2
Release pressure in the hydraulic reservoir to allow the
vacuum pump to be mounted (see Section 8000).
1) Coat the thread of reference (37) and (13) with loctite

or equivalent after removing any oil film and fasten by
tightening torque .
2) Apply packing liquid (69) to the connection of radiator hose after removing any oil film and fasten by tightening torque.
3) Tighten up the hose band from the direction schown
on the D.W.G.
Before operating the machine:
- Check the oil level in the hydraulic reservoir. Top up if
necessary.
- Check the hydraulic fluid cooling circuit for leaks.
- Fill and bleed the engine cooling system (see Operators Manual).
- Check the engine cooling system for leaks.
Lep SM4602001-0EN
Issued 09-07
Copyright
2001-4
ENGINE
Removal
STEP 7
Remove the engine retaining hardware.
STEP 1
NOTE: When installing, make a visual inspection of the

condition of the rubber flexible mountings and change
them if necessary. Tighten the engine retaining screws
to the torque specified in Section 1002.
STEP 8
When there is nothing interfering with the removal of
the engine, raise the engine carefully and install it on a
suitable repair bench.
STEP 9
Refer to Section 8003 and remove the hydraulic pump.
Installation
JS00163A
Park the machine on hard, flat ground. Lower the

attachment to the ground.
STEP 2
Release pressure in the hydraulic system and in the
hydraulic reservoir (see Section 8000).
STEP 3
NOTE: For the installation refer to the figure 1, page 6,

1) Coat the thread of reference (11), (35), (37), (41),
(43) and (49) with loctite or equivalent after removing
any oil film and fasten by tightening torque .
2) The elastic rubbers of reference (46) and (74) should
be assembled after confirming the discrimination color.
Before operating the machine, carry out the following
operations:
- Bleed and prime the fuel system (see Operators
Manual).
- Check the hydraulic, fuel and cooling systems for
leaks.
necessary.
CT07A009
Disconnect the earth cable (-) (1) from the battery.
STEP 4
Label and disconnect all the electrical connections from
the engine.
STEP 5
Remove all the clips, etc. which attach the electrical
harnesses to the engine and move out of the way.
STEP 6
Install a suitable lifting device on the engine lifting rings
(for the weight of the engine, see Section 1002).
Lep SM4602001-0EN
Issued 09-07
Copyright
2001-5
NOTES
.....................................................................................................................................................................................
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Lep SM4602001-0EN
Issued 09-07
Copyright
2001-6
ENGINE AND RADIATOR - FIGURE 1
330-5-02-02-24
Lep SM4602001-0EN
Issued 09-07
Copyright
2001-7
1 - SPL BOLT
2 - BUCKET
3 - ELBOW
4 - HYDRAULIC HOSE
5 - HYDRAULIC HOSE
6 - ELBOW
7 - GEAR PUMP
8 - HIGH STRENGTH BOLT
9 - HIGH STRENGTH WASHER
10 - BRACKET; MUFFLER
13 - BOND
14 - NUT; FLANGED
15 - BOLT; U
16 - MUFFLER
20 - SEAL CLAMP
22 - EXHAUST PIPE
24 - PLUG
25 - HOSE ADAPTER
26 - HOSE CLAMP
27 - AIR HOSE
28 - HOSE CLAMP
30 - BRACKET
31 - AIR-INLET PIPE
32 - BRACKET
33 - AIR HOSE
34 - AIR-INLET PIPE
37 - SEMS BOLT
38 - RADIATOR STAY
39 - HOSE BAND
40 - TUBE
41 - SEMS BOLT
42 - ENGINE SUPPORT REAR
45 - PLATE
46 - ELASTIC RUBBER
47 - SPL NUT
48 - SEMS BOLT
49 - ENGINE SUPPORT REAR
50 - HOSE BAND
51 - VINYL HOSE
52 - HOLDER
53 - SEMS BOLT
54 - RESERVE TANK
55 - BRACKET
56 - VACUUM SENSOR
Lep SM4602001-0EN
57 - ELBOW
58 - SPL JOINT
59 - HIGH STRENGTH NUT
60 - RUBBER HOSE
61 - ELBOW
62 - JUBILEE CLIP
63 - JUBILEE CLIP
64 - AIR-INLET HOSE
65 - ELBOW
66 - CLAMP
67 - SPL BOLT
68 - HOSE CLAMP
69 - LIQUID PACKING
70 - RADIATOR HOSE
71 - CLAMP
72 - BRACKET
73 - ENGINE SUPPORT FRONT
74 - ELASTIC RUBBER
75 - HYDRAULIC HOSE
76 - HYDRAULIC HOSE
77 - HYDRAULIC HOSE
78 - ENGINE SUPPORT FRONT
79 - BRACKET
80 - HOSE BAND
81 - BRACKET
82 - RADIATOR (STD) ASSY
83 - SPL LABEL
84 - AIR CLEANER
85 - AIR HOSE
86 - HARNESS BAND
87 - JUBILEE CLIP
88 - CLAMP
89 - ELBOW
90 - DIESEL ENGINE
91 - BRACKET
93 - HOSE CLAMP
94 - AIR HOSE
95 - HOSE CLAMP
96 - RADIATOR HOSE (IN)
97 - AIR-INLET PIPE
98 - RADIATOR STAY REAR
102 - BRACKET
103 - HOSE CLAMP
104 - CLAMP
105 - LIQUID PACKING
106 - BRACKET
107 - SEMS BOLT
108 - ENGINE; DIESEL
109 - SEMS BOLT
110 - HOSE CLAMP
Issued 09-07
Copyright
2001-8
NOTES
...........................................................................................................................................................................................
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Lep SM4602001-0EN
Issued 09-07
3001
Copyright
Section
3001
REMOVAL AND INSTALLATION
OF THE FUEL TANK
CNH
Lep SM4603001-0EN

Printed in France
September 2007
Copyright
3001-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
FUEL TANK .................................................................................................................................................................... 3
Removal ..................................................................................................................................................................... 3
Installation .................................................................................................................................................................. 4
Description ................................................................................................................................................................. 5
SPECIFICATIONS
See Section 1002.
Lep SM4603001-0EN
Issued 09-07
Copyright
3001-3
FUEL TANK
Removal
STEP 1
STEP 9
Remove the screws (8) and the protective plate (9).
STEP 10
Remove the screws (21) and the protective plate
(22).
STEP 11
Loosen the two screws (10) located under the
machine. Open the side portion of the machine and
remove the two screws (11) located on the RH side of
the fuel reservoir (1). Remove the protective plate
(12) of the reservoir.
JS00163A1

STEP 2
Reduce the engine speed to idle for 30 seconds, then
shut down the engine.
STEP 12
Attach labels on the hoses. Remove the hoses and
the retaining clips.
STEP 13
STEP 3
Shift the plastic protection (13) from the fuel sensor

(14). Remove the retaining screws (15) then the fuel
sensor (14) as well as the seal (16).
Turn the ignition key to "ON" without starting the

engine.
STEP 14
STEP 4
Remove the screws (17) and (20) from the fuel tank
(1), and the shims (18).
Attach a "DO NOT OPERATE" tag to the ignition key

in the cab.
STEP 15
STEP 5
Remove the fuel tank (1) using a hoist.
NOTE: The numbers within brackets refer to the figures on pages 5 and 6.
Remove the access panel under the fuel reservoir (1).
STEP 6
Open the filling plug (2) of the tank (1). Bleed the
remaining fuel using the valve (3) then remove the
latter. Remove the filter (19) and the fuel gauge.
STEP 7
Lift the hood of the front boot. Remove the retaining
screw (4) of the access ramp (5). Remove the access
ramp (5).
STEP 8
Remove the screws (6) on top and then inside the
front boot, then remove the protective housing (7).
Lep SM4603001-0EN
Issued 09-07
Copyright
3001-4
Installation
NOTE: The numbers within brackets refer to the figures on pages 5 and 6.
STEP 1
Using a hoist, position the fuel reservoir (1) on the
machine.
STEP 2
Install the shims (18) as well as the screws (17) and
(20), tighten the screws (17) to a torque of 225.6 to
264.8 Nm (166.39 to 195.31 lbf-ft). Install the valve
(3) and tighten the valve (3) to a torque of 14.7 Nm
(10.80 lbf-ft).
STEP 8
Install the protective housing (7) on top of the front
boot using the screws (6) then put back the screw
mask.
STEP 9
Install the access ramp (5) using screws (4). Close
the front boot.
STEP 10
Fill the fuel reservoir (see the operator's manual) and
make sure that there are no leaks.
STEP 3
STEP 11
Install a new seal (16), then the fuel probe (14) using
the five screws (15), reposition the plastic protection
correctly (13).
Reinstall the protective plate on top of the machine.
STEP 4
Install the hoses by taking help of the labels attached
during removal. Tighten using retaining clips.
STEP 5
Install the reservoir protection (12) using screws (10)
and (11). Tighten the screws (10) and (11).
STEP 6
Install the protective plate (9). Tighten the screws (8).
STEP 7
Install the protective plate (22). Tighten the screws
(21).
Lep SM4603001-0EN
Issued 09-07
Copyright
3001-5
Description
Location
6
11
12
5
11
10
21
22
20
4
5
6
7
8
9
10
11
12
20
21
22
SCREW
ACCESS RAMP
SCREW
PROTECTIVE HOUSING
SCREW
SKID PLATE
SCREW
SCREW
SKID PLATE
SCREW
SCREW
SKID PLATE
Lep SM4603001-0EN
Issued 09-07
Copyright
3001-6
Fuel tank
2
19
1
14
13
16
15
18
17
3
1
2
3
13
14
FUEL RESERVOIR
PLUG
VALVE
PLASTIC PROTECTION
FUEL PROBE
Lep SM4603001-0EN
15
16
17
18
19
SCREW
SEAL
SCREW
SHIM
FILTER
Issued 09-07
4001
Copyright
Section
4001
ELECTRICAL AND ELECTRONIC
CIRCUIT AND TROUBLESHOOTING
CNH
Lep SC4604001-0EN

Printed in France
March 2007
Copyright
4001-2
TABLE OF CONTENTS
ELECTRIC CIRCUITS OPERATION EXPLANATION ................................................................................................... 4
System Chart of Function .......................................................................................................................................... 4
ENGINE CONTROL ....................................................................................................................................................... 7
Fuel Injection Control (Common rail type) ................................................................................................................. 7
GENERAL LOCATION OF THE COMPONENTS (INSIDE THE CAB)........................................................................ 12
RELAYS AND MAIN FUSES (battery compartment) ................................................................................................... 13
FUSE BOX ................................................................................................................................................................... 14
WORK MODE SELECTION ......................................................................................................................................... 15
THROTTLE CONTROL................................................................................................................................................ 22
IDLING CONTROL (AUTO/ONE-TOUCH)................................................................................................................... 25
BREAKER MODE ........................................................................................................................................................ 27
AUTO PREHEAD (GLOW CONTROL) ........................................................................................................................ 28
AUTO WARM UP ......................................................................................................................................................... 31
OVERHEAT PROTECTION ......................................................................................................................................... 32
ATMOSPHERIC PRESSURE COMPENSATION ........................................................................................................ 33
CONTROL WHEN STARTING ENGINE...................................................................................................................... 34
CONTROL WHEN STOPPING ENGINE ..................................................................................................................... 35
EMERGENCY STOP OF THE ENGINE ...................................................................................................................... 35
ENGINE PROTECTION FUNCTION (EPF) ................................................................................................................. 36
FUNCTION LOCKING.................................................................................................................................................. 38
POWER BOOST .......................................................................................................................................................... 39
SWING BRAKE ............................................................................................................................................................ 40
TRAVEL MODE............................................................................................................................................................ 42
TRAVEL ALARM .......................................................................................................................................................... 43
POWER SHUT-OFF DELAY........................................................................................................................................ 44
CONTROL OF HYDRAULIC DRIVEN FAN ................................................................................................................. 45
FUEL SUPPLY PUMP CONTROL (AUTOMATIC STOP) OPTION............................................................................. 54
POWER TRANSISTOR PROTECTION ....................................................................................................................... 56
MONITOR DISPLAY .................................................................................................................................................... 57
Normal Display ......................................................................................................................................................... 57
Message Display ...................................................................................................................................................... 60
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-3
ACCESS AND CONTENTS OF MONITOR DISPLAYS (Diagnostic mode) ................................................................. 61
Access to monitor displays .......................................................................................................................................61
Machine condition .....................................................................................................................................................62
Diagnostic code ........................................................................................................................................................65
Machine history .........................................................................................................................................................70
Resetting ...................................................................................................................................................................73
MACHINE INFORMATION ........................................................................................................................................... 77
Setting of machine model .........................................................................................................................................77
Changing the language code ....................................................................................................................................79
Display of engine information ...................................................................................................................................79
Re-setting of engine information ...............................................................................................................................79
Selection of injector ..................................................................................................................................................80
TROUBLESHOOTING .................................................................................................................................................. 83
Prior inspections .......................................................................................................................................................83
Reading the organisation charts ...............................................................................................................................84
Procedures ...............................................................................................................................................................85
Fuel ...........................................................................................................................................................................86
Add coolant solution .................................................................................................................................................87
Low engine oil pressure ............................................................................................................................................88
Overheating ..............................................................................................................................................................89
Defective battery charge circuit ................................................................................................................................92
Electrical system troubleshooting .............................................................................................................................94
ELECTRICAL INSPECTION OF COMPONENTS ........................................................................................................ 96
Main pump proportional solenoid ............................................................................................................................100
6 solenoid valve bank .............................................................................................................................................100
Hydraulic oil temperature sensor ............................................................................................................................101
Pressure sensor ......................................................................................................................................................101
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-4
ELECTRIC CIRCUITS OPERATION EXPLANATION

System Chart of Function
ITEM
FUNCTION
Engine control
Work mode selection a) H/S/L mode
METHOD
Electronic control (common-rail)
Maximum engine speed, pump current,

and pressurizing solenoid valve are conMachine setting can be selected accordtrolled according to the selected work
ing to conditions such as of workload or
mode.
fuel efficiency preference, and lifting operation.
b) Auto-mode
Selection of auto-mode allows the load to

be calculated with pressure of negative
Suitable work mode is automatically
control P1 and P2 which in turn work
selected.
mode is switched.
c) Load prefectch control
Pump current is kept at 0 mA while
machine is not being operated.
Pump current and engine controller are

controlled by signal from pressure switch.
Throttle control
Engine can be controlled continuously Engine speed is adjusted by control of

from idling to high idling speed by opera- throttle valve.
tor's instruction.
Idling control
Engine speed can be switched to/form Pushing knob of switch on the right allows
idling by control of onetouch switch.
the engine to run idle and pushing it again
to return it as it was.
It makes engine to run idle while machine Selection of auto-idle allows the engine to
is not being operated.
run at idling speed automatically in 5 minutes after he lever is shifted to its neutral.
Shifting lever makes the engine to return
to its normal speed automatically.
Breaker mode
Pressing the breaker pedal allows the Turning ON the pressure switch in breaker
engine to run at the set speed automati- pilot line allows the engine to run at prevically and boosting pressure will be cut.
ously set speed. Also, pump current will
be set as that in S-mode and boosting
pressure is to be cut.
Auto preheat
It helps the engine to start easily at a low

temperature. Also, it stabilizes engine
speed immediately after start of the
engine to reduce exhausting smoke.
Auto warm-up
When coolant temperature is low, it allows In case where no operation of the

the engine to start warming up automati- machine after the engine has been started
cally after it has been started.
is carried out when coolant temperature is
low, it automatically increases engine
speed gradually to warm it up.
Overheat protection
When engine coolant temperature has When coolant temperature goes over
been increased, reduce injection quantity 100C, reduce fuel injection quantity.
to protect engine.
Coolant temperature sensor to ECM.
Lep SC4604001-0EN
Depending on cooling water temperature

at the time when the key switch is turned
ON, the glow plug is energized for a
period of time being set. It is to be energized for a certain period of set time after
the engine has been started to reduce
exhausting smoke.
Issued 03-07
Copyright
4001-5
ITEM
9
FUNCTION
METHOD
Correction of atmos- It prevents black smoke and engine dam- Fuel is to be restricted by an atmospheric
pheric pressure
age when intake air quantity is decreased sensor when altitude is over 2500 meters.
such as operating in highland.
10 Control on engine It increases fuel injection according to It monitors coolant temperature when it is
start
coolant temperature to improve starting under 0C. It watches a lapse of time after
performance.It improves starting perform- cranking has been started.
ance when sufficient fuel fails to be
injected due to wear in the machine as it
has been operated for a long time.
11 Engine stop control
12 Emergency
stop
13 Engine
function
Engine controller (ECM) recognizes It stops fuel injection from injector.It

engine key OFF by turning key switch insructs pressure control valve to opened
OFF
fully. It makes EGR valve to be fully open.
engine Emergency stop switch is set up with no Signal of emergency stop switch is transengine stop by key switch in mind.
ferred to engine controller (ECM) to perform engine stop control.
protection When the engine is operated with water Water temperature, boost temperature,
temperature, boost temperature, and and engine oil pressure are supervised,
engine oil pressure exceeded the level and engine is protected
respectively specified, it is to protect by
limitation of the engine output or by stopping the engine
14 Lever lock
It allows the machine not to be operated

by control of levers while cab is being
moved Up/Down or when the machine will
not be needed for operation.
15 Auto boost control
Boost control
When the lever is raised by control of the

gate lever on the left console, the lever
lock solenoid turns OFF which in turn pilot
pressure is cut off.
Whether boost of pressure is needed or

not is judged by the input data on load facIt increases main relief pressure by
tor of the engine and on pump discharge
approx. 10%.
pressure. (Boosting for 8 seconds.)
Boost -cut control
It does not allow boosting according to a
certain condition to protect machine and
equipment.
Boosting will not function when reserve

pressure switches are turned OFF.
16 Swing lock
It disables swing even when the swing Turning ON the swing lock switch allows
lever is mistakenly controlled.
the swing brake solenoid to be energized
to actuate mechanical brake.
17 Swing brake control
When swing lock is OFF, in order to protect swing device, it controls swing
mechanical brake ON/OFF automatically
according to operating conditions.
It controls swing brake solenoid valve by

the data obtained from switches of swing,
attachments, and travel pressure, and
also from pump discharge pressure.
18 Travel speed switch- It allows travel speed to switch to either It controls solenoid valve by the travel
ing-over
one of 2 levels.
mode switch to switch over tilt angle of
swash plate in the traction motor.
19 Travel alarm
Alarm buzzer functions when traveling.
Travel pressure
buzzer.
switch
controls
the
20 Power shut-off delay This ensures power supply for engine stop It allows a time-lag until main relay shuts
function.
off after key switch has been turned OFF.
21 Hydraulic driven fan It performs proper cooling control while
control
monitoring coolant temperature by driving
cooling fan hydraulically. With cleaning
mode. Low noise and low fuel consumption.
It controls fan motor speed by current output obtained by entering coolant temperature. Attached reversing function allows
radiator fan to be cleaned.
22 Fuel supply pump It makes an automatic stop when fuel tank Enter signal of fuel sensor to turn OFF
control
becomes full on refueling.
switch.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-6
ITEM
FUNCTION
METHOD
23 Power transistor pro- It protects controller in case where a cir- Over-current detection shuts off transistor
tection
cuit connected to transistor output is short- output.
circuited.
24 Travel speed switch- a) Normal display
ing-over
It displays current status of the machine.
b) Message display
Warning.
Functioning operation.
When to service the machine
Lep SC4604001-0EN
Temperature of hydraulic oil and of coolant

temperature, and fuel level are displayed
in bar graphs on LCD monitor and work/
travel mode is also displayed.
Each information is to be displayed by letters on LCD monitor.
Issued 03-07
Copyright
4001-7
ENGINE CONTROL
Fuel Injection Control (Common rail type)
1. Process to determine quantity of fuel injection
1) System diagram
Engine control module (ECM)
CAN communication
Basic fuel injection amount
Shovel
Controller
Boost pressure sensor input

CKP sensor input
CMP or G sensor input
Correction
Engine coolant temperature correction
Barometric Pressure
Fuel temperature boost pressure correction
Correction between cylinders
Q-key correction
QR correction
ECT Sensor input
Correction
SCV or PCV
opening time
determination
Injector coil energizing time

Timing determination
Common rail pressure sensor
Common rail
Injector coil
SCV or PCV
Injector
Supply pump
Fuel tank
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-8
2) Operation
Engine controller (ECM) gets information (signal from mounted sensors) such as engine speed and engine load.
Based on the information, ECM sends electric signals to supply pump and to injector to make a proper control of fuel
injection quantity and injection timing for each cylinder.
1) Injection quantity control
Based mainly on engine speed and load given to actual machine, Injection rate control is carried out for optimum
injection by controlling fuel injector.
2) Injection pressure control
Injection pressure is controlled by control of fuel pressure in the common-rail.
The right pressure in the common-rail is calculated by using engine speed and fuel injection quantity.
The supply pump and the pressure control valve are controlled according to the calculated pressure so that it can
discharge proper quantity of fuel to pressure-feed into the common-rail for control.
3) Injection timing control
The control substitutes timer function and an appropriate fuel injection timing is calculated by mainly using engine
speed and fuel injection quantity to control the injector.
4) Injection rate control
In order to improve fuel consumption in the cylinder, a small amount of fuel is injected (pre injection) for ignition at
first, then 2nd time injection (main injection) into the ignited cylinder is carried out.
In this control, the injection quantity control in section 1) and the injection timing control in section 3) are carried out
by controlling injector.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-9
2. Mounting position of accessories related to engine

B3 B50
B51 B47
B1
B49
M9
B6
B48
Engine
harness
connector
S62
R5
A2
EST
connector
Tech 2
connector
ECM memory
clear
700.1.04.01.28F
A2
B1
B3
B6
B47
B48
B49
Engine controller
Coolant temperature sensor
Fuel temperature sensor
Air intake temperature sensor
Boost pressure sensor
Atmospheric pressure sensor
Crankshaft position sensor (or engine speed sensor (flywheel mounted))
Lep SC4604001-0EN
B50 Camshaft position sensor (or G sensor: cylinder

recognition sensor (detects rotation of cam shaft))
B51 Boost temperature sensor
M9 Air conditioner condenser fan motor
R5 Fuel sensor
S62 Air cleaner sensor
Issued 03-07
Copyright
4001-10
3. Appearances of accessories related to the Tier 3 emission control regulation

A2. Engine controller (ECM)
700-1-04-01-23AF
Controller for the engine meeting Tier 3 emission control regulation (hardware is common to the vehicle).
Quantity of pin is 121 as against 104 for the engine meeting Tier 2 emission control regulation.
Reliability is equivalent to the unit for current engine meeting Tier 2 emission control regulation (evaluation of single
unit has been completed).
In area indicated by an arrow, ISUZU part number and TRANSTRON part number, and serial number are recorded.
B1. Coolant temperature sensor
B3. Fuel temperature sensor
700.1.04.01.23AI
700.1.04.01.23AG
1 Power, positive (+)

2 Power, negative (-)
3 For water temperature indicator (not in use)
B6. Intake air temperature sensor
700.1.04.01.23AH
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-11
B47. Boost pressure sensor
B50. Camshaft position sensor (or G sensor)
700.1.04.01.23AM
B51. Boost temperature sensor
700.1.04.01.23AK
B48. Atmospheric pressure sensor
700.1.04.01.23AH
R5. Fuel level sensor
700.1.04.01.23AJ
1 Power, positive (+)

2 Power, negative (-)
3 Output
B49. Crankshaft position sensor

700.1.04.01.23AO
S62. Vacuum sensor

Operating negative pressure: 6.27 0.29kPa.
700.1.04.01.23AL
Lep SC4604001-0EN
700.1.04.01.23AN
Issued 03-07
Copyright
4001-12
GENERAL LOCATION OF THE COMPONENTS (INSIDE THE CAB)
M3 A4
S54
S15
S16
S51
P1
S63 S14
S17
R3
S53
S1
S64
P6
S13
E4
E52
E51
F21
X8
A1
A2
B61
K5
K6 K32 K11 K10 K3
K2 K33
U1
CS01M598A
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-13
A1
A2
A4
B61
E4
E51
E52
F21
K2
K3
K5
K6
K10
K11
K32
K33
Computer
Engine controller
Wiper controller
Sunload sensor
Cab light
Cigarette lighter
Air conditioner
Fuse box
Relay-glow plug
Relay-horn
Relay-rotary light
Relay-air conditioner condenser fan
Relay-working light (upperstructure/attachment)
Relay-working light (cab)
Relay, hydraulic fan
Main relay
M3
P1
P6
R3
S1
S13
S14
S15
S16
S17
S51
S53
S54
S64
U1
X8
Wiper motor
Instrument panel
Air conditioner control panel
Throttle volume
Key switch
Overload switch
Breaker/crusher switch
Horn switch
One touch idle
Boom raising priority switch
Hydraulic function cancellation lever switch
Door limit switch
Front window limit switch
Cooling hydraulic motor switch
DC-DC (24 V-12 V) converter
Radio connector
RELAYS AND MAIN FUSES (BATTERY COMPARTMENT)

F23
F24
F25
F22
K7
K8
700.1.04.07.20A2
1 Battery cable
F22 Fuse 20 A; main fuse for F11 and F12 circuits
F23 Fuse 65 A; main fuse for F3 to F10 and F13 to F20
circuits
F24 Fuse 20 A; main fuse for F2 circuit
F25 Fuse 20 A; main fuse for F1 circuit
K7 Relay battery
K8 Relay safety
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-14
FUSE BOX
CM00E005
F1
Fuse 20 A:
Engine controller
F2
Fuse 5 A:
Computer control, instrument panel and diagnostic test socket
F3
Fuse 20 A:
Computer power
F4
Fuse 10 A:
F5
Fuse 10 A:
Air conditioner condenser fan
F6
Fuse 10 A:
Rotary light
F7
Fuse 30 A:
Fuel filler pump
F8
Fuse 20 A:
Fuel feed pump
F9
Fuse 30 A:
Glow plug
F10 Fuse 20 A:
Lubricator (option) connector
F11 Fuse 10 A:
Back-up
F12 Fuse 20 A:
Key switch
F13 Fuse 20 A:
Heater /air conditioner
F14 Fuse 5 A:
Air conditioner compressor
F15 Fuse 15 A:
Working light (upperstructure/attachment)
F16 Fuse 15 A:
Working light (cab) and option connector
F17 Fuse 10 A:
DC-DC (24V - 12V) converter
F18 Fuse 15 A:
Wiper and washer
F19 Fuse 15 A:
Horn
F20 Fuse 15 A:
Cigarette lighter and cab seat compressor adjustment
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-15
WORK MODE SELECTION

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

S4 Auto mode switch
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-16
3) Mode selection switch
4) Operation
1. If the machine was in H/S/L mode and was turned

off by the key switch, it will restart in S-Mode when it
is turned on through the key switch again. (The previous data is reset.)
1. Pushing the mode switch on the monitor display will

send a signal to the controller. The controller then
switches modes according to the signal it received.
2. By pressing the work mode switch (S3), the modes

alternate as follows: SHLSH.
3. No matter what mode is selected (S4) to start with,
pushing the auto-mode switch (S4) once will switch
the mode to auto. Pushing the switch again will
switch the auto-mode to S-mode, regardless of the
mode that was selected prior to auto-mode.
4. During the auto-mode operation, the work mode
switch stays deactivated. The switch will not work to
change modes.
5. After the machine has been turned off with auto-mode
selected, it will restart in the auto-mode even when the
key switch is turned on. (Previous data is retained.)
2. The controller signals the currently selected mode to

the monitor via serial communication. The LCD screen
switches according to the data sent.
3. The controller transmits the current mode to the
engine controller via CAN communication. The engine
controller regulates the engine governor according to
the data.
4. Also, the engine controller transmits via CAN communication the data on current mode and the actual
engine speed.
5. The controller determines the pump current based on
the following data: current mode, actual engine speed,
target engine speed. The controller then transmits the
result to the pump.
6. The LCD on the monitor switches, reflecting the transmission received from controller via serial communication.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-17
5) Switches and LCD
P4
S2
H1
S3
S5
S4
S22
S7
S10
S9
S8
S11
P5
S12
CD00E007A
H1
P4
P5
S2
S3
S4
S5
S7
S8
S9
S10
S11
S12
S22
S22
Audible warning device

Monitor display
Hourmeter
Travel mode switch
Work mode switch
Auto mode switch
Cushion control switch
Audible alarm cut out switch
Swing brake switch
Emergency engine stop switch
Working light switch
Wiper switch
Washer switch
Rotary light switch (Europe only)
Free swing switch (North America only)
Lep SC4604001-0EN
P4
6
CS00F521
1
2
3
4
5
6
Travel speed indicator

Work mode indicator
Idle mode indicator
Coolant temperature indicator
Hydraulic oil temperature indicator
Fuel level indicator
Issued 03-07
Copyright
4001-18
A) Auto Modes
1) Alteration
The current value of I min in mode H is changed to that value equivalent in mode L.
The engine speed sensing control is carried out even in mode S and I maxi is set to the current value equivalent in
mode S and I min to that equivalent in mode L.
The engine speed sensing control is carried out even in auto mode and control it within the range from I maxi to I
min (equivalent in mode L) for both Sa and La.
2) Purpose
It lowers pump output automatically to cope with drop of engine power due to use of poor quality fuel and operation in
highland.
It applies optimum load with fuel cost and cycle time in mind when operated in automatic mode.
Y7
P1
A1
A2
1
700-1-04-01-23AP
1 Engine
A1 Computer
A2 Engine controller
P1 Instrument panel
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-19
Max.torque point = X engine speed
H mode
A
Torque
L mode
900
0.5
4.5
Engine horsepower
Target speed (min-1)
S mode
A mode
H mode
S mode
Horsepower
L mode
5.0
Trottle volume (V)
HImax ((1) mA)
900
Quantity of flow (Q)
Engine speed (min-1)

SImax ((2) mA)
H mode
S mode
Imin=L mode ((3) mA)
Pressure (P)
P-Q chart of pump
700.1.04.01.23AT2
Mode H:
When engine speed is between A rotation and X rotation at maximum torque point, it controls current value
range from HI maxi ((1) mA) to I min ((3) mA).
Mode S:
When engine speed is between B rotation and X rotation at maximum torque point, it controls current value
range from SI maxi ((2) mA) to I min ((3) mA)
Mode L:
When engine speed is C rotation, current value is of
mode L ((3) mA).
Auto mode:
Sa:
When engine speed is between B rotation and X rotation at maximum torque point, it controls current value
range from ((1) mA) to l min ((3) mA).
La:
When engine speed is between C rotation and X rotation at maximum torque point, it controls current value
range from HI maxi ((1) mA) to I min ((3) mA).
Lep SC4604001-0EN
4) Operation in mode H, S, and L

1. When the target speed of the engine is lower than the
speed at maximum torque, the pump current comes to
the current value in mode L even if it is operated in
mode H or S. (To prevent engine stop).
2. When operating travel alone even it is operated in
mode L, the current value in mode S is to be taken (to
prevent endless travelling).
3. When using a backup line (breaker, crusher etc.), the
current value in mode S is to be taken.
4. Even if it applies to the section 2) or 3) above, the current value in mode L is to be taken in the case of section 1). (To prevent engine stop.)
5. .When in auto idling, put the idling engine speed at
1200 min-1. (For measures against black smoke generated when restoring engine speed by manual control of lever).
Issued 03-07
Copyright
4001-20
6. When temperature of engine cooling water is too low
or when power-supply voltage applied to the engine
controller is too low, increase the idling speed to prevent over-cooling and/or running out of battery.
5. Operation in auto mode
1. When auto mode has been selected, start the
machine with mode La first then select mode Sa
according to working conditions.
2. In addition, the mode can be changed automatically
from Sa to La.
3. When water temperature is less than 50C (122F)
and oil temperature is less than 25C (77F), control in
auto mode will not be carried out even if the auto
mode has been selected and the mode is fixed to La
selected on starting.
4. Once water temperature reaches more than 50C

(122F) and oil temperature more than 25C (77F)
however, control in auto mode starts and continues
operating in this mode if water and/or oil temperature
is dropped again.
5. If travel pressure switch is turned ON during control in
auto mode, work mode will not be changed over while
it is being turned ON.
6. (If travel pressure switch is turned ON during control
in mode Sa, mode Sa is to be held, and similarly if
the switch is turned ON during control in mode La,
this mode is to be held).
Set value in each mode

Mode
Designation
Unit
(MAX)
(When travelling)
H
Pump current
Engine speed
2000
-1
min
Engine speed
Set value
-1
min
(I MAX)
mA
490
(I MIN)
mA
240
(When in no control)
mA
< 50
-1
min
1800
(I MAX)
mA
405
(I MIN)
mA
240
mA
< 50
(MAX)
min-1
1700
(STD)
mA
< 50
mA
< 50
(MAX)
min-1
1800
(I MAX)
mA
490
(I MIN)
mA
240
(MAX)
min-1
1700
(I MAX)
mA
490
(I MIN)
mA
240
mA
< 50
min-1
900
(MAX)
S
Pump current
Engine speed
L
Pump current
Engine speed
Mode Sa
Pump current
Engine speed
Mode La
Pump current
Engine speed in idling

Engine speed in auto idling
Engine speed at maximum torque
Lep SC4604001-0EN
min
-1
1200
-1
1500
min
Issued 03-07
Copyright
4001-21
B) Load pre-fetch control

1) Purpose
Pump current is controlled as measures against black smoke.
Y7
B26
1
A2
B27
A1
700.1.04.01.23AU
1 Engine
A1 Computer/Controller
B26 Upper pilot pressure switch (yellow band)

B27 Travel pilot pressure switch
3) Operation
1. .When no operation is carried out (attachment and
travel pressure switches OFF), the pump current is
always 0 mA regardless of operation mode and
engine speed.
2. .When attachment or travel pressure switch is turned
ON, the controller provides pump current so that it can
get to the set current for the work mode being selected
after 0.8 second.
* No control for decreasing transient load has been
employed for machines above current model of
CX330.
Control for decreasing transient load is illustrated
below:
Since engine response (or returning property) has
been improved (or no difference between target speed
and actual speed), if an abrupt engagement of the
lever from inching operation is carried out, and when
difference between target speed and actual speed
reaches within 150 min-1, pump current of 0 mA is to
be applied to ease the engine load.
This is for the purpose of taking measures against
black smoke and of prevention from engine stop.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-22
THROTTLE CONTROL
The analog voltage signal from throttle potentiometer is provided to the controller in the machine to transfer it to the
engine controller (ECU) via CAN communication circuit together with work mode.
1) Purpose
Engine speed can be set by no dependence of the engine controllers on ISUZU side.
TARGET SPEED
ENGINE SPEED
5V
SIG
THROTTLE VOLUME
GND
A1
CAN-H
A2
CAN-L
ENGINE
CONTROLLER
ENGINE CONTROLLER
H mode
5.0
S mode
Input voltage (V)
L mode
B
C
A mode
900
100
Throttle Volume Position (%)
0.5
4.5
5.0
Input voltage (V)

700.1.04.01.23AV
1 Engine
3) Operation
1. The controller determines the target speed from the
position of throttle potentiometer and the work mode
currently being entered to transfer the data to the
engine controller (ECM) via CAN communication circuit.
2. ECM determines fuel injection quantity from the calculated target speed and the data obtained from each
sensor (such as actual engine speed, fuel temperature, and boost temperature) to transfer it to the supply
pump and to the injector for engine control.
4. When CAN communication linking between the controller and the engine controller (ECM) is stopped,
the engine speed is fixed to a certain specified
speed and the throttle potentiometer specifying
engine speed will not be functioning. (Specified
speed: 1050min-1).
The specified speed, for the purpose of emergency
escape, has been set as the engine speed which
will not damage the breaker while the engine is running.
3. When the engine is rotated at a speed less than that at

the maximum torque by controlling throttle potentiometer, the pump current becomes that of mode L even if
work mode is selected either to mode S or to mode H.
Lep SC4604001-0EN
Issued 03-07
1
2
3
CONTROLLER
CN.50
ENGINE STOP
CN.52
G1 G2 ACC M ST
1.25RW 4
2
5
3
6
1
21
11
4
5
43
29
39
ENGINE STOP
CAN H
CAN L
5V THROTTLE
SIG THROTTLE VOLUME
A GND
24VB
HEAT
OFF
ACC
ON
ST
1.25LgR
0.85GrR
0.85LY
0.85LG
0.85BL
3
4
6
7
8
1.25LgR
0.85GrR
0.85LY
0.85L
0.85BL
CN.A0
ENGINE STOP
MONITOR SWITCH
0.85P
0.85PL
BrR
0.85LY
0.85LG
0.85BL
WR
1.25RW
1.25RW
2
3
5
1.25LgR
WR
0.85GrR
1.25LgR
WR
0.85GrR
1.25GR
1.25GR
WR
0.85LgR
GrR
BrR
YR
0.85P
0.85PL
3LR
2LR
16 WR
17 0.85LgR
18 GrR
19 BrR
20 YR
21 P
22 PL
MAIN RELAY
WR
1.25LgR
BATTERY RELAY
0.85Y
0.85YL
0.85BY
1
3
2
0.85BO
0.75OL
SAFETY RELAY
t C
AIR INTAKE
TEMP. SENSOR
CN.A1
BARO SENSOR
1
2
GLOW RELAY
0.85GrR
B48
ENGINE CONTROLLER (ECM)
1.25B
1.25B
1.25B
0.85BG
0.85BG
0.85BG
1.25GR
1.25GR
BrR
CN.19
THROTTLE
VOLUME
1.25LgR
0.85GrR
YR
0.85LgR
YR
BL
0.85LY
0.85L
0.85BL
P
PL
18
37
1
3
4
43
62
81
2
5
10
CN.6
CN.1
21
24
40
41
0.85LgR
LgR
GrR
0.75Y
0.75WR
0.75W
0.75RG
CN.3
GrR
WR
0.85BY
0.85Y
BL
BL
0.75L
0.85YL
0.75OL
WR
KEY SWITCH
74 0.75WL
79 0.75BY
80 0.75YR
CN.22
CN.21
A1
CN.23
S9
46
47
60
61
63
64
67
71
72
K33
83
84
89
95
CN.A8
0.75W
0.75GR
0.75YG
0.75G
0.75WG
0.75R
0.75W
0.75W
0.75G
0.75L
CN.A7
103 0.75GB
CN.T3
97
91
92
93
94
87
82
90
101
98
B6
100 0.85BL
5
1
2
3
4
2LR
YR
BG
1.25GR
Lep SC4604001-0EN
K2
3LR
0.75WB
0.75GB
0.75YB
0.75WG
0.75G
0.75YG
0.75GR
0.75R
0.75W
0.75G
0.75G
0.75L
BW
0.75L
BL
0.75WR
0.75WL
0.75RG
0.75GR
0.75BR
0.75RY
0.75YB
0.75BY
0.75GR
0.75Y
0.75P
0.75W
1
2
1
2
3
4
5
6
12
13
14
1
2
3
5
6
7
15
8
16
17
9
10
11
8
7
6
4
3
2
1
0.75GW 5
0.75WL 6
0.75GB 7
8
0.75G
0.75WB 9
0.75WR 10
1.25RG
1.25RW
CN.A5
0.75P
0.75G
0.75L
0.85BW
0.75BR
0.75YB
0.75WB
R3
CN.A2
105
106
107
108
109
110
111
S1
K8
5
1
2
3
4
1
CN.A4
2WR
LgR
BrR
2LR
K7
CN.A6
0.75P
0.75WB
0.75WR
1.25RW
0.75G
0.75WL
0.75GW
0.75GB
1.25RG
GLOW PLUG
No.4 CYLINDER
No.2 CYLINDER
No.3 CYLINDER
No.5 CYLINDER
No.6 CYLINDER
No.1 CYLINDER
PCV2
PCV1
FUEL LEAKAGE
TEMP. SENSOR
t C
OIL PRESS.
SENSOR
BOOST PRESS.
SENSOR
BOOST TEMP.
SENSOR
t C
WATER TEMP.
SENSOR
t C
G(MRE) SENSOR
CRANK ANGLE
(MPU) SENSOR
COMMONRAIL
PRESS. SENSOR
U
V
W
EGR POSITION
SENSOR
U
V
W
EGR MOTOR
M15
113
114
115
116
117
118
119
120
121
ENGINE
Copyright
4001-23
4) Throttle Control Relation Electric Circuit Diagram
B53 B52 B49 B50 B1 B51 B47 B21 B3 Y33 Y34
R1
CN.A3
A2
700-1-04-01-23 aw
Issued 03-07
Copyright
4001-24
1 Engine
A1 Computer
B1 Coolant temperature sensor
B3 Fuel temperature sensor
B6 Air intake temperature sensor
B21 Engine oil pressure switch
B47 Boost pressure sensor
B48 Ambient air (barometric) pressure sensor
B49 Crankshaft position sensor
B50 Camshaft position sensor
B51 Boost temperature sensor
B52 Common rail pressure sensor
B53 Exhaust gas recirculation valve position sensor
K2 Relay-glow plug
K7 Relay battery
K8 Relay safety
K33 Main relay
M15 Exhaust gas recirculation motor
R1 Glow plug
R3 Throttle volume
S1 Key switch
S9 Engine emergency stop switch
Y33 Supply pump valve (pcv1)
Y34 Supply pump valve (pcv2)
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-25
IDLING CONTROL (AUTO/ONE-TOUCH)

P1
B26
H1
B27
S16
B25
P4
A1
A2
B22
1
700.1.04.01.1.23AX
1 Engine
B22 Swing pilot pressure switch
B25 Breaker pilot pressure switch
B26 Upper pilot pressure switch (yellow band)
B27 Travel pilot pressure switch

H1 Audible warning device
P1 Instrument panel
P4 Monitor display
S16 One touch idle
2) Switching between auto idle and one-touch

idle
8. LCD displays IDLING on the monitor during idling

control.
1. Pushing the knob switch (IN1) down and holding it

for 3 seconds will trigger the modes to toggle
between auto and one-touch. When the mode
switches, the ON/OFF display on the auto idle section of the LCD also switches, and the buzzer
buzzes for 3 seconds.
3) Switching between auto idle and one- touch
2. At the time of auto idle/one-touch idle selection, the

previous setting will still prevail even after the key
switch was turned ON. (Previous data is retained.)
3. The LCD will display ON/OFF status of auto idle.
ON on the display indicates the auto idle, OFF indicates one-touch idle.
4. If there occurs no handling through the lever for 5
seconds with auto idle turned ON (both attachment
pressure switch and travel pressure switches are
OFF), the engine speed automatically goes back to
the idling state. (For 5 seconds, the initial setting
prevails. Programming is possible through adjusting
settings on the back panel for the duration between
1 and 30 seconds.)
5. During auto idle, if operated via lever while engine is
idling (either attachment pressure switch or travel
pressure switch is on), the engine speed automatically goes back to the previous rate.
6. Even during auto idle, idling/recovery operation is
attained by pressing the knob switch (one-touch
switch).
idle
1. When setting idling revolutions based on conditions
described in 2). Switching between auto idle and
one-touch idle, the controller transmits an idling signal to the engine controller via CAN communication.
Also, a signal is sent to the monitor display via serial
communication to display IDLING on the screen.
2. The engine controller, upon receiving the signal,
selects idling mode and adjusts engine speed to
that of the idling state.
3. The monitor displays IDLING on the LCD according to the signal sent.
4. When recovering from idle control based on the
conditions described in 2). Circuit configuration, the
controller transmits a signal to the engine controller
via CAN communication conveying the previous
engine mode selection. Also, the serial transmission
that has been sent to the monitor for displaying
IDLING on the screen will be terminated.
5. The engine controller, depending on the mode signal received, switches the idling mode back to the
previous mode and adjusts the engine speed.
6. The monitor recognizes the termination of the idling
signal transmission and stops the IDLING display
on LCD.
7. When auto idle is OFF (i.e. during one-touch idle),

idling/recovery is attained by simply operating the
knob switch (one-touch idle switch), whether or not
the machine was manoeuvred though the lever.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-26
4) Timing diagram
1) Timing diagram for auto idle ON/OFF selection
POWER 24V
0V
IN1 OFF (5V)
(KNOB SW) ON (0V)
AUTO IDLE
700-1-04-01-23 AY2
2) Timing diagram when auto idle is ON
IN1 OFF (5V)

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

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

(KNOB SW) ON (0V)
IN2 OR IN3 OFF (5V)
ON (0V)
ENGINE SPEED
IDLE
700-1-04-01-23 BA2
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-27
BREAKER MODE
1. Alteration
Optimization of pump current in mode S and in mode
L at the engine speed with the breaker being used.
Pump current at engine speed of between 1200 and
1500min-1 is applied from that in mode L to that in
mode S.
2. Purpose
Although in the breaker mode up to now, pump current
in mode S is to be applied at engine speed of more
than 1500 min-1, It spreads the speed range in mode
S so that the machine can be operated in less than
that of the flow-rate.
R3
Y7
1
S14
B25
A2
A1
700.1.04.01.23BB
1
A1
A2
B25
Engine
Computer/Controller
Engine controller
Breaker pilot pressure switch
R3 Throttle volume
S14 Breaker/crusher switch
4) Operation
1. When the breaker mode switch is turned ON by
locker switch on the console (left side) and the pressure switch in backup line is turned ON, it controls
to rotation of the breaker.
2. When the engine is rotated at a speed less than that
set for the breaker by controlling the throttle potentiometer, engine speed will not be increased to the
speed set for the breaker even if the breaker is operated.
3. If the pressure switch in backup line is turned ON
regardless of breaker mode switch input, the pump
current is to be at the current value in mode S irrespective of operation of at that time. (However, when
the engine speed is less than 1200min-1, pump current becomes that in mode L).
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-28
AUTO PREHEAD (GLOW CONTROL)

ture, at the same time when the key switch is turned
ON.
1) Alteration
Only the circuit structure and the pre-glow control are
different. (Refer to time chart attached) It is the same
that the pre-glow starts, according to water tempera2) Circuit configuration
ENGINE CONTROLLER
KEY SWITCH
S1
ST
CONTROLLER
A2
OFF
ENGINE
GLOW
PLUG
ON
ST
TO BATTERY RELAY
TO STARTER RELAY
K2
GLOW RELAY
A1
ENGINE START
KEY ON
CAN-H
GLOW RELAY
CAN-L
700.1.04.01.23BC
1 Engine
K2 Relay-glow plug
S1 Key switch
3) Operation
1. When the key switch is turned ON, the engine controller (ECM) calculates pre-glow time from engine
cooling water by using the attached map.
2. ECM turns ON the glow relay output during calculated pre-glow time to transfer the glow lamp signal
through CAN communication circuit to the controller
displaying ENGPREHEAT on the monitor.
3. The glow relay output continues regardless of ON/
OFF of the glow lamp signal.
6. Since the control mentioned above starts immediately after the key switch has been turned ON,
ENG PREHEAT will not be displayed on the monitor unless the pre-glow time passes more than 3
seconds (below -5C) (23F).
*The glow lamp time map is added from the engines
meeting the emission control regulation of 3rd-stage.
*Refer to attached sheets for the glow control time
according to water temperature and for the time chart.
4. After the engine has been started, it turns ON the

glow relay output again only when cranking the
engine. The glow lamp signal will not be transferred
at this time.
5. When the key switch returns to ON from the start
(when cranking is completed), it calculates afterglow time by using the attached map. The glow lamp
signal will not fee transferred at this time.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-29
4) Water temperature control map
GLOW LAMP TIME (sec)
1) Glow lamp time (it transmits by CAN communication)
C
-4
14
50
68
32
ENGINE COOLANT TEMPERATURE
86
104 F
700-1-04-01-23 BD2
PRE GLOW TIME (sec)
2) Pre-glow time
-4
14
50
68
32
86
C
104 F
700-1-04-01-23 BE2
AFTER GLOW TIME (sec)
3) After glow time
-4
14
68
50
32
86
C
104 F
700-1-04-01-23 BF2
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-30
5) Timing chart
1) When in normal operation
START
KEY
SWITCH
ON
OFF
ON
GLOW
LAMP
OFF
ON
GLOW
RELAY
OFF
GLOW LAMP TIME
PRE GLOW TIME
AFTER GLOW TIME

700-1-04-01-23 BG2
2) When the engine has been started after pre-glow is completed

START
ON
KEY
SWITCH
OFF
GLOW
LAMP
OFF
ON
ON
OFF
GLOW
RELAY
GLOW LAMP TIME
PRE GLOW TIME
CRANKING
GLOW TIME
AFTER GLOW TIME
700-1-04-01-23 BH
3) When the engine has been started before glow lamp goes off
START
KEY
SWITCH
GLOW
LAMP
GLOW
RELAY
ON
OFF
ON
OFF
ON
OFF
GLOW LAMP TIME

PRE GLOW TIME
CRANKING
GLOW TIME
AFTER GLOW TIME

700-1-04-01-23 BI2
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-31
AUTO WARM UP
R3
B26
H1
S16
A2
P4
A1
700.1.04.01.23BJA
1
A1
A2
B26
Engine
Computer/Controller
Engine controller
Upper pilot pressure switch (yellow band)
H1 Audible warning device

P4 Monitor display
R3 Throttle volume
S16 One touch idle
2) Operation
1. A coolant temperature sensor is installed inside the
engine. The signal from this sensor goes out to the
engine controller and is converted into a temperature value. The engine controller then transmits the
coolant temperature data to the controller via CAN
communication.
5. Once auto warm-up control is cancelled, the controller does not initiate auto warm-up control again
unless key switch is turned from OFF to ON.
6. While controller is executing the auto warm-up control, an AUTO WARM UP message is displayed on
the monitor's LCD.
2. If the coolant temperature is below 50C (122F)

after engine starts, the controller transmits the auto
warm-up signal to the engine controller via CAN
communication.
3. The engine controller executes the auto warm-up
control upon receiving the signal transmission from
the controller.
4. The controller terminates the auto warm-up control
on the following conditions. The engine controller
terminates the auto warm-up control once the command is cancelled.
*When one of the following switches turns on: attachment pressure switch, travel pressure switch, and
knob switch (one-touch idle switch).
*When throttle volume is changed.
*When engine speed stays above 1800 min-1 for 3
minutes.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-32
3) Auto warm-up control
AUTO WARM-UP
COMPLETE
ENGINE SPEED (MIN -1)
ENGINE SPEED (MIN -1)
AUTO WARM-UP
COMPLETE
TIME
THROTTLE
POSITION
TIME
THROTTLE
POSITION
DURATION OF OPERATION
DURATION OF OPERATION
700-1-04-01-23-BK2
OVERHEAT PROTECTION
water temperature exceeds 100C (212 F).
* Waning OVER HEAT is to be displayed on the
monitor in actual machine when temperature exceeds
105C (221 F).
1) Purpose
It is the function protecting the engine by restriction of
fuel injection quantity which in turn reduces engine out
put forcibly when water temperature has kept on rising.
The control starts functioning at the moment when
2) Water temperature-fuel injection quantity
Q RESTRICTION BY OVERHEAT PROTECTION
Q RESTRICTION RATE (%)
120
100
80
60
40
20
32
95
100
105
110
115
120
125
203
212
221
230
239
248
257
C
266 F
130

700.1.04.01.23BL2
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-33
ATMOSPHERIC PRESSURE COMPENSATION

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

FUEL COMPENSATION
1032
TORQUE
959
885
811
737
664
590
(m)
1640
3285
4921
6562
8202
9842
11483
13123
14764
16404 (ft)
ALTITUDE
450.1.04.01.28AO
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-34
CONTROL WHEN STARTING ENGINE

1) Starting control (by monitoring water temperature
1. Purpose
When water temperature is below 0C (32F), Purpose is to ensure starting performance of the engine
in cold temperature by making fuel injection according

to water temperature.
2) Long cranking control

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

1. Fuel quantity to be injected by faulty injectors is allotted to other normal injectors (total quantity is to be the
same).
1. Purpose
Purpose is to correct fuel injection quantity to assure
starting performance of the engine with a view to
escaping in an emergency when a certain number of
stopped injectors are detected by trouble diagnosis.
2. In case where number of faulty cylinders is over half of

the total numbers, increase of fuel injection.
2. Operation
3. Number of cylinders-Correction factor
Number of effective cylinders
Correction factor
Lep SC4604001-0EN
1.0
1.2
1.5
2.0
1.0
1.0
1.0
Issued 03-07
Copyright
4001-35
CONTROL WHEN STOPPING ENGINE

1. Operation
1) Turn OFF the key switch.
2) When the engine controller recognizes that the
key is turned OFF, steps 3) through 5) below are
carried out simultaneously.
3) Fuel injection quantity stops to be calculated.
4) Pressure control valve (PCV) is instructed so that
it is fully closed.
5) EGR valve is instructed so that it is fully closed

and its initial point is corrected.
6) After steps 3) through 5) have been completed,
information such as history failure is written in
EPROM in the ECM.
7) Turn OFF the main relay and turn OFF the power
supplied to ECM.
EMERGENCY STOP OF THE ENGINE

1. Alteration
In current type 3 (engine meeting emission control regulation of 2nd-stage), depression of the emergency stop switch
allows the engine stop motor to rotate to the stop position by way of the relay and allows the engine governor to control for stopping engine by the engine stop signal from the engine controller (ECU).
In the next type (engine meeting emission control regulation of 3rd-stage), depression of the emergency stop switch
allows the controller to transfer engine stop signal to ECM controlling the engine to be stopped.
2. Circuit configuration
MONITOR DISPLAY
24V-OUTPUT
CN6-21(PNP)
P4
ENGINE STOP
WR501
1
BrR530
CN3-43
S9
SWITCH
(EMERGENCY STOP)
A1
A2
CONTROLLER
ENGINE CONTROLLER
ENGINE
700.1.04.01.23BO
1 Engine
P4 Monitor display
S9 Engine emergency stop switch
3. Operation
1) Depression of emergency stop switch on the monitor display allows the output signal from transistor
in the controller to be turned ON and at the same
time, the engine stop signal is transferred from the
controller to the engine controller (ECM)
2) ECM performs stopping control for the engine.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-36
ENGINE PROTECTION FUNCTION (EPF)

1) Purpose
When the engine is operated with water temperature, boost temperature, and engine oil pressure exceeded the level
respectively specified, it is to protect by limitation of the engine output or by stopping the engine.
2) Operation
1) Water temperature monitoring
Setting
Time
100C
105C
Engine control
Indication in bar graph for ECM: Decrease of fuel injection rate

Machine controller: Normal
water temperature:
Error
codes
Reset
Monitor
message
M00F0
Indication in bar graph for

water temperature:
Below 8th graduation
At 8th graduation
110C
5 sec.
ECM: Decrease of fuel injection rate

Machine controller: Idling
M00F1
120C
5 sec.
ECM: Decrease of fuel injection rate

Machine controller: Engine stop
M00F2
OVER
HEAT
Turn ON key after engine

has been stopped.
1. Engine protection will not function if error codes, E0117 (water temperature sensor low voltage abnormality)
and E0118 (water temperature sensor high voltage abnormality), are indicated.
2. Engine protection will not function if error codes, E2104 (CAN-bus abnormality), E2106 (CAN time-out abnormality), and M0090 (CAN communication error), are indicated.
3. Engine protection by water temperature will start functioning 1 minute after the engine has been started (in
order to detect water temperature in steady state).
2) Boost temperature monitoring
Setting
Time
80C
5 sec.
90C
5 sec.
Error
codes
Reset
ECM: Normal
Machine controller: Idling
M00F3
When temperature below

70C continues for 30
sec.
ECM: Normal
M00F4
Engine control
Monitor
message
OVER
HEAT

has been stopped
1. Engine protection will not function if error codes, E1112 (boost temperature sensor low voltage abnormality)
and E1113 (boost temperature sensor high voltage abnormality), are indicated.
3. Engine protection by boost temperature will start functioning 1 minute after the engine has been started (in
order to detect boost temperature in steady state).
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-37
3) Engine oil pressure monitoring
Setting
Time
40KPa
5 sec.
Engine control
ECM: Normal
Error
codes
Reset
Monitor
message
M00F5

has been stopped
LOW OIL
PRESS
1. Engine protection will not function if error codes, E0522 (engine oil pressure sensor low voltage abnormality)
and E0523 (engine oil pressure sensor high voltage abnormality), are indicated.
3. Engine protection will not function if error code of E1633 (5V power supply 3 voltage abnormality) is indicated.
4. Engine protection by engine oil pressure will start functioning 30 seconds after the engine has been started (in
order to detect engine oil pressure in steady state).
*Introduce failure codes of machine system for setting error codes.
*Pump output is always functioning according to L mode while idling.
*Turning key switch OFF allows function of engine protection to be reset. (Engine runs for 30 sec. even if something
is wrong.)
*Error codes are to be recorded as well as recording other codes.
*The engine is to be stopped by means of emergency engine stop signal from PNP output.
*The engine is to be judged as started if it runs at a speed of more than 500 min-1.
4) Select for setting of engine protection function
Since engine protection function has been set as standard, the setting can also be cancelled.
RESET (RST1)
Selection of engine
protection function
Engine protection function

(0=ON, 1=OFF)
800-1-04-01-26F
1. Every time the traveling mode switch turns ON, the setting at AU is to be shifted as in the order of
00000001001000110000 repeatedly.
2. Turn ON the operation mode switch for 10 seconds.
3. Buzzer sounds to indicate that the settings have been memorized.
4. Turn the OFF key switch.
*If NO against engine protection function is chosen, function of engine output limitation/engine stop is cancelled but
error codes are displayed and saved as records.
NOTE: At "AU" selection, auto boost control and engine protection function can be set at the same time.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-38
FUNCTION LOCKING
F21
K7
F4
F23
Y2
S51
G1
700.1.04.01.23BP
F4
Fuse 10 A; hydraulic function cancellation lever

switch
F21 Fuse box
F23 Fuse 65 A; main fuse for F3 to F10 and F13 to F20
circuits
G1 Battery
K7 Relay battery
S51 Hydraulic function cancellation lever switch
Y2 Pilot pressure solenoid valve (blue band)
2) Timing diagram
KEY
SWITCH
POWER
GATE BAR
POSITION
RUN
STOP
LEVER LOCK
SOLENOID VALVE
OPERATION
ENABLE
DISABLE
700-1-04-01-23 BQ2
3) Operation
1) By positioning the gate lever on cab console (left)
toward operation (gate lever sticks out when this is
done) while the machine is powered on, the limit
switch will be turned ON (closed) and the lever lock
solenoid valve will be ON.
2) When the lever lock solenoid valve is ON, pressure
can reach the pilot line, enabling the machine to operate.
Lep SC4604001-0EN
3) By positioning the gate lever toward entering/leaving cab (gate lever stays housed), the limit switch will
be turned OFF (open) and the lever lock solenoid
valve turns OFF.
4) When the lever lock solenoid valve turns off, pressure cannot reach the pilot line. Thus the operation of
the machine will be disabled.
Issued 03-07
Copyright
4001-39
POWER BOOST
A2
B42
A
B44
B27
Y5
B25
A1
700.1.04.01.23BR
A
A1
A2
B25
B27
B42
B44
Y5
Main relief (standard)

Computer
Engine controller
Travel pilot pressure switch

Pump pressure sensor (P1)
Pump pressure sensor (P2) (yellow band)
Power-up solenoid valve (yellow band)
2) Increasing the pressure in each work mode

Mode Auto
Automatic power boost (*)

31.4 to 34.3 MPa (4554 4974 psi)
H mode
(Pressure)

31.4 to 34.3 MPa (4554 4974 psi)
S mode
(Pressure)

31.4 to 34.3 MPa (4554 4974 psi)
L mode
(Pressure)
Constant power boost (*)

31.4 to 34.3 MPa (4554 4974 psi)
* When the travel pilot pressure switch (B27) or the optional breaker pilot pressure switch (B25) is activated, power boost
is deactivated.
3) Operation
When operating in H or S mode, the computer (A1)
records the ratio between:
- The engine load transmitted by the engine controller (A2).
- The hydraulic circuit load transmitted by the pump
pressure sensors (P1) (B42) and (P2) (B44).
Lep SC4604001-0EN
If the pump pressure (P1) or (P2) is greater than 29.9

MPa (4351 psi) and the load ratio is within a range of
5% for 2 seconds, the computer (1) activates the
power-up solenoid valve (yellow band) (Y5) for 8 seconds, which increases the main pressure.
When the travel pilot pressure switch (B27) or the
optional pilot pressure switch (B25) is activated, the
computer (A1) deactivates the power-up solenoid valve
(yellow band)(Y5).
Issued 03-07
Copyright
4001-40
SWING BRAKE
S8
B22
B26
S1
B27
B42
B44
Y3
P1
A1
700.1.04.01.23BS
1 Swing brake
A1 Computer
B22Swing pilot pressure switch
B26Upper pilot pressure switch (yellow band)
B27Travel pilot pressure switch
B42Pump pressure sensor (P1)
B44Pump pressure sensor (P2) (yellow band)

P1 Instrument panel
S1 Key switch
S8 Swing brake switch
Y3 Swing brake solenoid valve (pink band)
2) Operation of the swing brake control

1) Overview
1. Pressing the swing lock switch on monitor display will turn on the red LED, activating the swing lock control.
Pressing the swing lock switch again will turn off the LED, and the swing lock is deactivated.
2. During swing lock control, controller's transistor output turns on and the mechanical brake that is built in the
swing motor turns on.
3. The ON/OFF state of the swing lock holds when turning the key switch from OFF to ON.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-41
2) Timing diagram
KEY SWITCH
POWER
SWING LOCK
SWITCH
OUT
(IN1)
SWING
PRESSURE
SWITCH (IN3)
SWING LOCK
LED
700-1-04-01-23 BT2
3) Swing brake auto control

1) Overview
The auto control of the swing brake takes place when the swing lock is OFF.
The auto control also releases the mechanical brake automatically during a digging operation as well as during swing
operation. If the operation is halted, the auto control turns on the mechanical brake automatically.
The detailed conditioning for ON/OFF of the swing mechanical brake is shown below.
The swing brake will be turned OFF based on the following conditions.
1. Pressure switch (swing) is ON
2. P1>15 MPa (2175 psi) or P2>15 MPa (2175 psi)
The swing brake will be turned ON based on the following conditions.
1. Pressure switch (attachment) stays OFF for 5 seconds
2. Key switch is OFF
The swing mechanical brake will be deactivated once when the pump delivery pressure (P1 or P2) grows over 15
MPa (2175 psi) during travel. However, it will take effect in 5 seconds.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-42
TRAVEL MODE
P1
A1
B42
B44
S2
B43
B27
Y4
P4
700.1.04.01.23BU
P1
P4
S2
Y4
A1 Computer
B42Pump pressure sensor (P1)
B43Pressure sensor (nega-cont.)
B44 Pump pressure sensor (P2) (yellow band)
Instrument panel
Monitor display
Travel mode switch
2 stage travel solenoid valve (red band)
2) Timing diagram
Power supply
24 V
Travel mode
switch
ON
OFF
IN1
5V
0V
Speed
0V
II
II
II
II
700-1-04-01-23 BV
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-43
3) Operation
Travel speed II selected
When the starter motor switch is positioned in the

ON position, the 1st speed is selected by default.
1. When the pressure of the pumps P1 or P2 is less

than 580 psi, the output from the computer
(OUT)(A1) of the 2 stage travel solenoid valve (Y4)
is deactivated (1st speed).
Every time the travel mode switch is pressed (S2), the

computer (A1) registers a signal (IN1: 0 volts).
The computer (A1) changes the travel speed in the following way I-> II, II -> I and transmits the modifications
to the monitor display (P4).
Travel speed I selected
The output from the computer (OUT)(A1) of the 2 stage
travel solenoid valve (Y4) is deactivated (1st speed).
2. When the pressure of the pumps P1 or P2 is greater

than 580 psi, the output from the computer
(OUT)(A1) of the 2 stage travel solenoid valve (Y4)
is activated (2nd speed).
When the attachment controls are operated, the output from the computer (OUT)(A1) of the 2 stage
travel solenoid valve (Y4) cannot be activated or
deactivated.
3. When the travel pressure is greater than 3582 psi,
the travel motor displacement change spool is
pushed back and the swash plate angle is in high
displacement (1st speed).
4. Travel speed II may still be selected if necessary, for
example for cleaning tracks.
TRAVEL ALARM
Pressure switch
(Travel)
B27
Travel alarm
Controller
H2
A1
700.1.04.01.23BW
A1 Computer
H2 Travel alarm
2) Timing diagram
The pressure switch (travel) will be turned ON through the travel lever operation. The travel alarm will sound for 10 seconds, then stop.
Power
Travel alarm
700.1.04.01.23BX
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-44
POWER SHUT-OFF DELAY

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

S1 Key switch
3) Timing diagram
KEY SWITCH
S1
ENGINE SPEED
ON
OFF
7 sec.
MAIN RELAY
K33
ON
OFF
4 sec.
BATTERY RELAY
K7
4 sec.
ON
OFF
700-1-04-01-23BZ
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-45
CONTROL OF HYDRAULIC DRIVEN FAN

1) Outline of control
Main control of hydraulic driven fan is illustrated below.
Detailed description for each section is shown after next section.
1)
2)
3)
4)
5)
Fan speed control according to water temperature

Spool stick prevention control
Engine start/stop control
Reversing fan control (cleaning mode)
Actual fan speed checking mode
2) Basic circuit configuration
A1
ENGINE CONTROLLER
CONTROLLER
ENGINE
TARGET SPEED
THROTTLE
VOLUME
R3
5V
SIG
CAN-H
GND
CAN-L
A2
a
FAN REVERSING
SWITCH
S64
5V
ENGINE SPEED
ENGINE COOLANT TEMP.
FAILURE CODE
FAN MOTOR
MONITOR
KEY SWITCH
UART
S1
M9
P1
24V
Y31
FAN REVERSING
SOLENOIDE VALVE
PNP out
24V
S51
GATE LIMIT
SWITCH
LEVER LOCK
SOLENOID
Y1
RELAY
Y32
PWM out
ELECTROMAGNETIC
PROPORTIONAL VALVE
FOR CONTROLLING
FAN SPEED
PWM return
700.1.04.01.23CA
a)
b)
1
A1
A2
R3
S1
Target speed information,

Engine speed, engine coolant temperature and
failure mode information
Engine
Computer/ controller
Engine controller
Throttle volume
Key switch
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-46
1. Fan speed control according to water temperature

Set the fan rotation at a low speed to prevent over-cooling and carry out quicker warming-up when engine cooling
water temperature is low, and conversely, set the fan at a proper speed to realize low noise and low fuel consumption
when engine cooling water temperature is high.
1) Outline
1) The controller calculates command current value from the map illustrated below according to engine cooling water
temperature transferred from the engine controller through CAN communication circuit and then transfers the
command current to PWM out (electromagnetic proportional valve for controlling fan speed) so that the fan may
rotate at a speed in response to the command current.
2) Judged value of fan speed at the command current value is to be decided only at the maximum and at the minimum rotation (values shown in Fig. below are both at oil temperature of 50C (122F)), therefore, the fan speed
at medium range varies from fan to fan.
2) Engine cooling water- Command current characteristics
ENGINE SPEED
(min-1)
1570 +100
0
HIGH IDLING
FAN SPEED
1570
IDLING
COMMAND CURRENT VALUE
REF.
VALUE
max.1000
(500)
(mA)
600
550
500
450
400
350
300
250
200
150
100
50
0
RADIATOR COOLANT
TEMPERATURE
80
START
WORKING
83
85
RANGE
90
95
100
FULL OPEN
105
(C)
MAX.COOLING
CONDITION
THERMOSTAT FUNCTIONING
700.1.04.01.28BE
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-47
3) Back-up operation
1) When failure code illustrated below appears, it allows the command current supplied from the controller to the
electromagnetic proportional valve for control fan speed to be 0 mA. In addition, when failure code illustrated below occurs, the error will not be returned as fan rotation may become unstable due to poor connection and the like.
Failure codes related to engine system
E0335
:
Crank sensor trouble
E0340
:
G sensor trouble
E2104
:
CAN-bus trouble
E2106
:
CAN time-out
E0117
:
Trouble with water temperature sensor in low voltage
E0118
:
Trouble with water temperature sensor in high voltage
Failure codes related to mechanism
E0070
:
Key switch error
E0090
:
CAN communication error
2) When the message ELEC PROBLEM is displayed on the monitor due to functioning of power transistor protection, it allows the command current stated above to be 0mA.
4) Time chart (back-up operation)
START
START
KEY SWITCH
ON
ON
OFF
FAILURE CODE
ON
OFF
BACK UP
600mA
PMW out
Fan speed control based

on water temperature.
Spool stick prevention
control.

on water temperature.
Spool stick prevention
control.
0mA
700-1-04-01-23CC
2. Spool stick prevention control

Spool stick is a phenomenon that the spool with clearance seal is stuck because actuating force of the spool is increased by building-up of fine particles in the oil to the clearance seal when a certain position in the spool is loaded
with hydraulic force for a long time.
In order to avoid this, following control is carried out.
Spool stick prevention control for electromagnetic proportional valve for control fan speed
1) Outline
1) When the engine is started by key switch and the engine speed increases to reach 300min-1 (engine is judged as
started) or more, spool stick prevention current (100mA) is delivered from PWM out in the controller at regular
intervals (every 1min.) for a certain time (50m sec.).
2) Although the spool stick prevention current is delivered at regular intervals (every 1min.), when command current
value obtained by fan speed control according to water temperature is larger than that of spool stick prevention
current, the control becomes invalid and the spool stick prevention current stated above will not be delivered. (Refer to figure below).
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-48
2) Time chart
Invalid range of spool stick prevention
mA)
600
Command current
500
400
300
Fan speed control according

to water temperature
1 min 1 min
200
50 msec
100
Time
700-1-04-01-23CD
Solenoid valve for reversing fan Spool stick prevention control

1) Outline
Engine key ON/OFF mode
1) When the key switch is turned ON and 2 seconds have passed, spool stick prevention signal is delivered from
PNP out in the controller for a certain period of time (20msec.).
2) When the engine is started within 2 seconds after the key switch has been turned ON, the spool stick prevention
signal stated above will not be delivered.
3) Similarly, after the key switch has been turned OFF too, the spool stick prevention signal is delivered from PNP
out in the controller for a certain period of time (20msec.).
2) Time chart
Power-cut delay
START
KEY SWITCH
ON
OFF
ON
POWER SUPPLIED
TO CONTROLLER OFF
2sec
SOLENOID VALVE
FOR REVERSING
FAN
20msec
20msec
ON
OFF
800.1.04.01.26IA
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-49
3. Engine start/stop control

1) Engine start control
When the engine has been started, lower the fan speed (to restrain surge pressure on discharging side of pump) to
carry out following control for easing load in starting engine.
1) Turning the key switch ON allows the controller to supply current of 600mA to PWM out (electromagnetic proportional valve for control fan speed).
2) When the engine is started by key switch and the engine speed increases to reach 300min-1 (engine is judged as
started) or more, PWM out in the controller shifts to fan speed control according to water temperature and
spool stick prevention control.
2) Engine stop control
In order to prevent cavitation due to fan rotation by inertia when the engine has been stopped, following control is
carried out.
1) Turning the key switch OFF allows the controller to supply current of 600 mA to PWM out (electromagnetic proportional valve for controlling fan speed).
2) PWM out in the controller keeps on supplying current of 600mA while Power-cut delay is functioning.
3) Time chart
Power-cut delay
START
KEY SWITCH
ON
OFF
POWER SUPPLIED
TO CONTROLLER
ON
OFF
SOLENOID VALVE
FOR REVERSING
FAN
Spool stick prevention control

OFF
Judgment of start
300min-1
ENGINE SPEED
STOP
600mA
600mA
Fan speed control according to water

temperature.
Spool stick prevention control.
PWM out
0mA
Fan speed control according to water

temperature.
FAN SPEED
STOP
700-1-04-01-23CF
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-50
4. Reversing fan control

Flowing direction of air is reversed by reversing fan revolution so that trifling dust clogged in the radiator core is possible to be removed.
Since heat radiation capacity declines while the fan rotation is being reversed by which overheat of the engine becomes possible, do not operate any control lever.
Change over of mode
1) Outline
1) Turning ON fan reversing switch (momentary) after the key switch has been turned ON allows the fan to change
rotation from normal mode to reverse mode.
During this period, the buzzer gives warning sound of 2Hz from the monitor to inform that the fan is rotated in
reverse mode. When the reversing switch is turned ON again, it changes rotation from reverse to normal and the
buzzer stops sounding.
2) For reverse mode, previous data are to be reset.
This means that turning OFF the key switch in either of mode, reverse or normal, allows it to be operated in normal
mode when the key switch is turned ON next time.
3) When warning message OVER HEAT is displayed on the monitor, it will not be operated in reverse mode. The
fan reversing switch functions and the mode can be switched over after overheated condition is released and
warning message OVER HEAT is disappeared from the monitor.
4) When the message ELEC PROBLEM is displayed on the monitor due to functioning of power transistor protection, it will not be operated in reverse mode as stated above.
2) Time chart
KEY SWITCH
FAN REVERSING
SWITCH
MODE
ON
OFF
ON
ON
ON
ON
ON
OFF
Normal
Reverse
Normal
Reverse
Normal
Normal
Reverse
700-1-04-01-23CG
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-51
Function of reversing fan
1) Outline
1) When the fan reversing switch (momentary) is turned ON after the key switch has been turned ON, reversing signal is delivered to the fan reversing solenoid valve to allow the fan to change rotation from normal mode to reverse
mode.
And at the same time, a signal is transferred to the lever lock relay from PNP out in the controller and the lever
lock solenoid valve turns OFF.
This allows the machine operation to be impossible regardless of where the gate lever is positioned.
At this time, command current from PWM out in the controller drops from 600mA to 0 mA.
2) Starting the key switch in the situation above allows the engine to be started in fan reverse mode and the fan
rotates at maximum speed as the command current value from PWM out in the controller is 0 mA.
3) When the key switch is turned OFF in reverse mode, it switches to be operated in normal mode when the key
switch is turned ON again because previous data are to be reset.
4) Even if it has set up the auto-idle during reversal operation, an auto-idle dose not function.
2) Time Chart
START
ON
KEY SWITCH
OFF
FAN REVERSING
SWING
ON
OFF
SOLENOID VALVE
FOR REVERSING FAN OFF
(PNP out)
LEVER LOCK
OFF
SOLENOID VALVE
(PNP out)
MONITOR BUZZER
ON
ON
Normal mode
ON=2Hz sounds
OFF
MODE
Max.speed
Max. speed
Normal mode
Reverse mode
ENGINE SPEED
(TARGET PEED)
Low speed
Low speed
STOP
600mA(WT< 90C)
600mA
PWM out
0mA
Max. speed
FAN SPEED
STOP
700-1-04-01-23 CH
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-52
5. Checking mode of actual fan speed

The actual fan sped is possible to be checked as the fan speed can be set at any point within a certain range by
operation of the switch.
1) Outline
1) Command current of PWM out in the controller can be set at any point by 10mA pitch within the range of between
100mA and 600mA at OUT in RST1 (reset) screen in Service support indication (refer to service support
items for operation) on the monitor.
2) After OUT is selected on the reset screen (refer to figure below) with the buzzer stop switch, displayed figures
change every time the travel mode switch is turned ON.
Displayed figures show command current and indication immediately after selection is command current value at
present.
Once the travel mode switch is turned ON, it shows figures 0100 and every time switch is turned ON, the figures
change by 10 as illustrated below.
->0100->0110->0120->0130->0140->0150->0550->0560->0570->0580->0590->0600-> Current value at present
3) For confirmed fan rotation check mode, data in last time are reset.
That is, even if the key switch has been turned OFF with the current set at a certain value, it will be turned in normal mode when the key switch is turned ON next time.
2) Service support screen
This mode is to be used to check if the fan speed changes according to current variation.
6. Fan speed control according to oil temperature

Fan speed control according to oil temperature is added and the temperature of the hydraulic oil is prevented from
overheating.
1) Outline
1) The controller adjusts the instruction current value to 0mA more than the temperature shown from the temperature of the hydraulic oil transmitted from the sensor of the temperature of the hydraulic oil in the figure below.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-53
2) Temperature of the hydraulic oil - Command current characteristics
Ref. value
Command current value
Control start point of

temperature of oil
Fan speed control according

to water temperature
(176
Fan speed control according to

oil temperature
(185
(194
Hydraulic oil temp.
(203
(212
(C)
(F)
450.1.04.01.32A
3) Back-up operation
1) When failure code illustrated below appears, it allows the command current supplied from the controller to the
electromagnetic proportional valve for control fan speed to be 0 mA.
In addition, when failure code illustrated below occurs, the error will not be returned as fan rotation may become
unstable due to poor connection and the like.
Failure codes related to mechanism.
M0020: Trouble with hydraulic oil temperature sensor in low voltage
4) Time chart (back-up operation)
START
START
ON
ON
KEY SWITCH
OFF
FAILURE CODE
ON
OFF
BACK UP
600mA
PMW out

on water and oil
temperature. Spool stick
prevention control.

on water and oil
temperature. Spool stick
prevention control.
0mA
700-1-04-01-23CC
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-54
FUEL SUPPLY PUMP CONTROL (AUTOMATIC STOP) OPTION

1) Control outline
The controller detects fuel quantity by fuel sensor allowing the fuel supply pump to make an automatic stop when the
fuel tank is filled up.
Fuel tank
Battery relay
Fuel sensor
Fuse 20A
Battery
Rf
Controller
R5
K7
SIG
GND
A1
G1
Re
S61
Main relay
(for fuel supply pump) (Manual)
(Automatic)
3-position roker switch

(*1)
Fuel supply
pump)
K30
K31
CN6-17(PNP)
Motor
BZ
M14
GND
(*2)
Switch
Relay
(automatic)
(*1) Fuel supply pump: Made by JABSCO (manufacturer in UK).
(*2) Buzzer: Same buzzer used as travelling alarm to MSR.
700-1-04-01-23CK3
*All components other than controller, battery, and fuel level sensor are stored in the tool box (in house in front-right).
A1
G1
K7
K30
K31
M14
R5
S61
Computer/controller
Battery
Relay battery
Refuel pump relay
Refuel pump stop relay
Fuel feed pump motor
Fuel sensor
Refuel pump switch
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-55
3) Operation
1) Automatic stop
1. Assemble it with the switch built-in the fuel supply pump turned ON. (No control is required for customers.)
2. Put the 3-position rocker switch to Automatic side after the key switch has been turned ON. (Center: OFF,
Automatic Alternate: ON, Manual: Momentary ON.)
3. This operation allows electric power to be supplied to the fuel supply pump by way of both relays of auto
and main so that fuel is pumped up into the fuel tank out of an fuel drum.
4. The controller is always monitoring quantity of fuel remained in the tank by using fuel sensor.
5. When the fuel sensor comes to the full level (Rf) position or above, the controller gives output signal to the
relay (auto). (NPN output.)
6. The relay (auto) is switched over by the output signal allowing the power supplied to the fuel pump to be shut
off.
7. At the same time, the buzzer sounds to inform that refueling has been made an automatic stop.
8. When the 3-position rocker switch is turned OFF, the buzzer stops sounding and automatic refueling mode is
released.
9. Even if the automatic refueling mode has been released, the controller keeps on sending output signal to the
relay (auto) if the position of fuel sensor is at the full level (Rf) or above.
10. The controller stops giving the output signal to the relay (auto) when the fuel sensor comes down below the
full level (Rf) position.
2) Manual refueling
1. In case where automatic refueling fails functioning due to troubles such as in the fuel sensor, the controller,
and the relay (auto).
2. In case where a machine cannot fill up the fuel to its full by automatic refueling.
3. Supply fuel while monitoring fuel gauge with the 3-position rocker switch turned to manual side (momentary).
4. Power is supplied to the fuel supply pump via the relay (main) from the manual switch so that fuel can be supplied to the tank.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-56
POWER TRANSISTOR PROTECTION

CONTROLLER
24V (PNP)
17
FUEL SUPPLY PUMP
18
FREE SWING (NA) BEACON (EU)
19
TRAVEL ALARM
21
ENGINE STOP (EMERGENCY STOP)
22
HYDRAULIC DRIVEN FAN REVERS
27
SWING BRAKE
28
29
2-SPEED TRAVEL
22
CUSHION
30
31
SWING SHUT-OFF
32
BACKUP 1
20
BACKUP 2
700-1-04-01-23 CL
In the event that a solenoid valve or a relay develops a short circuit, the power transistor output will be shut off in
order to protect the controller. A ELEC PROBLEM message will be displayed during the failure. Perform the service support check to have the location of failure pinpointed and displayed.
Then follow the display result and inspect the wire or the equipment that seems to be experiencing the failure.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-57
MONITOR DISPLAY
1
CD00E007A2
1. Fuel level indicator

2. Hydraulic oil temperature indicator
3. Coolant temperature indicatora2
Normal Display
1.Radiator coolant temperature
A1
A2
B1
P4
SCALE
104 122 140 158 176 194 212 230

COOLANT TEMPERATURE
700-1-04-01-23CN2
A1 Computer/controller

P4 Monitor display
2) Operation
1. Coolant temperature sensor is installed inside the engine. The signal from this sensor (Vtw) will be transmitted
to engine controller as an analog signal (voltage).
2. The engine controller converts the transmitted signal into a temperature value. It then transmits this coolant
temperature data to the controller via CAN communication.
3. When the controller receives the signal, it uses to the graph shown above to determine the bar graph display
level for the signal level. The controller then transmits the data to monitor display via serial communication.
4. When the monitor display receives transmission, it reflects the data received as a bar graph on the display.
5. OVER HEAT will be displayed when level 8 lights up on the scale. (The engine does not stop.)
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-58
2. Hydraulic oil temperature
P4
B2
A1
SCALE
C
68
86
104
122
140
158
176
194
212
OIL TEMPERATURE
700-1-04-01-23CO
B2 Hydraulic oil temperature sensor
P4 Monitor display
2) Operation
1. Hydraulic oil temperature sensor is installed inside the suction piping. The signal from this sensor (Vto) will
be transmitted to controller as an analog signal (voltage).
2. When the controller receives the signal, it first converts it into a temperature value. The controller then uses
to the graph shown above to determine the bar graph display level for the signal level. The controller then
transmits the data to monitor display via serial communication.
4. OVER HEAT will be displayed when level 8 lights up on the scale.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-59
3. Fuel level
P4
B3
A1
700-1-04-01-23 CP2
B3 Fuel temperature sensor
P4 Monitor display
Remaining fuel (L)
Fuel sensor
resistance (W)
Input voltage
Vf1 (V)
Bar graph
480 <
10 to 18
0.455 to 0.766
420 to 480
18 to 24
0.766 to 0.964
364 to 420
24 to 30
0.964 to 1.142
300 to 364
30 to 37
1.142 to 1.337
244 to 300
37 to 46
1.337 to 1.582
136 to 244
46 to 61
1.582 to 1.891
81 to 136
61 to 75
1.891 to 2.138
< 81
75 to 80
2.138 to 2.222
1 (Refill fuel)
2) Operation
1. Fuel sensor is installed inside the fuel tank. The signal from this sensor (Vf1) will be transmitted to the controller as an analog signal (voltage).
2. When the controller receives the signal, it uses to the graph shown above to determine the bar graph display
level for the signal level. The controller then transmits the data to monitor display via serial communication.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-60
Message Display
START
MESSAGES DISPLAYED
KEY SWITCH ON
KEY SWITCH AND ENGINE RUNNING
ELEC PROBLEM
ALTERNATOR
LOW OIL PRESS
AIR FILTER
LOW FUEL
LOW COOLANT
WARNING
YES
NO
OVER HEAT
ENG IDLING
AUTO WARMUP
POWER UP
ENG PRE HEAT

SERVICE DUE
MODE DISPLAYS
H : SUPER HEAVY MODE
S : REGULAR MODE
L : FINISHING MODE
AUTO : AUTO MODE
TRAVEL MODE DISPLAT

I : LOW-SPEED TRAVEL
II : HIGH-SPEED TRAVEL
AUTO IDLE DISPLAYS
ON : AUTO IDLE
OFF : ONE-OUCH IDLE
700-1-04-01-23 CQ
Buzzer
Message Display
Meaning and Measures to be Taken
ENG PRE HEAT
Engine warm up (glow) is indicated.
AUTO WARN UP
Indicates automatic warming of the engine. The automatic warming is released by moving the throttle volume or operation levers.
ENG IDLING
Indicates the engine is running at low idling.
POWER UP
Indicates the system is in automatic digging power up.
SERVICE DUE
At the time of every 500 hour service intervals, one minute indication appears for 5
times when the engine starts.
Sounds
LOW FUEL
Sounds
LOW COOLANT
Indicates the coolant water level is low. Add coolant water.
Sounds
LOW OIL PRESS
Indicates the engine oil pressure is abnormally low. Stop the engine, check engine oil
level and add oil.
Sounds
OVER HEAT
Sounds
ALTERNATOR
Sounds
ELEC PROBLEM
Sounds
AIR FILTER
Lep SC4604001-0EN
Indicates the fuel level is very low. Add fuel.
Indicates the engine coolant temperature or hydraulic oil temperature abnormally rises.
Put the engine in low idling and reduce water or oil temperatures.
Check the radiator & oil cooler.
Indicates problems in battery charging system. Check the electric circuit.
Indicates electric problems (short circuit or disconnection) in the electric system.
Check the electric circuit.
Indicates the air filter clogged.
Air filter are cleaned or exchanged promptly.
Issued 03-07
Copyright
4001-61
ACCESS AND CONTENTS OF MONITOR DISPLAYS (Diagnostic mode)

Access to monitor displays
Normal
display
H
Status
display
Machine
I information
(a)
Service support
display
(b)
Diagnostic
trouble
B
B
Usage
history
B
Reset
D
B
CHK7
C
CHK1
C
CHK5
CHK2
CHK6
CHK3
C
CHK4
C
CHK5
C
DIAG1
HR 12
C
DIAG2
C
D
C
DIAG3
C
D
HR 9
C
D
C
DIAG6
HR 10
C
DIAG4
DIAG5
HR 11
HR 8
C
HR 7
HR 1
RST1
C
HR 2
RST2
J
C
HR 3
C
HR 4
C
HR 5
C
HR 6
C
RST11
C
RST12
C
RST13
C
RST14
C
RST15
C
RST16
C
800.1.04.04.08A
a) Bar graph (Hydraulique oil temperature, coolant temperature, fuel level)

b) Mode (Travel, work, auto, idle)
Operating Switches
A.
B.
C.
D.
E.
To be switched after the travel & work mode switch has

been turned ON for more than 3 seconds.
To be switched when the auto mode switch is turned
ON.
To be switched when the buzzer stop switch is turned
ON.
Data is to be cleared after the work mode switch has
been turned ON for more than 10 seconds (buzzer
sounds when the data have been cleared).
Reset function is to be selected when the buzzer stop
switch is turned ON, the selected function is to be
reset when the travel mode switch is turned ON, and
the data are to be reset after the work mode switch
has been turned ON for more than 10 seconds (buzzer
sounds when the data have been reset).
Lep SC4604001-0EN
F.
G. Output with the protection circuit actuated is to be
checked when the travel mode switch is turned ON.
H. Automatic detection of short circuit is to be indicated
after the travel mode switch has been turned ON for
more than 10 seconds.
I. To be switched after the auto mode switch has been
turned ON for more than 10 seconds.
J. Selected machine model is be cleared after the auto
mode switch has been turned ON for further 10 seconds (buzzer sounds when it has been cleared).
K. To be switched after the one-touch idle switch has
been turned ON for more than 10 seconds at anytime
while the service support screen is being displayed.
Issued 03-07
Copyright
4001-62
Machine condition
1. Machine condition CHK1
CHK
MODE II H
ENG
2000
rpm
1
P1
030.0
MPa
0300
mA
P2
030.0
MPa
WT
0080
MODE:
P1:
P2:
N:
ENG:
I
03.00
MPa
OT
0055
WT:
OT:
Travel - work
Main pump (P1) pressure
Main pump (P2) pressure
Negative pressure (N)
Engine rpm
Pump control current value
Fan motor current value (when Travel Mode
switch ON))
Radiator coolant temperature
Hydraulic oil temperature
Intake air temperature (only when Travel
Mode switch ON))

CHK
MODE II H
TR1
2
R
0080
TR2
R:
Engine load ratio
FT:
Fuel temperature
Boost temperature (only when Travel
Mode switch ON)
TV:
TR1
TR2
TR3
TR4
Throttle volume degree of opening

Controller transistor output
0000
0000
FT
0000
TR3
0000
TV
0100
TR4
0000
Transistor output: 0 = OFF; 1 = ON

TR1 0 0 0 0
TR2 0 0 0 0
TR3 0 0 0 0
Swing brake
Free swing (NA)
2-speed travel
Soft/hard (EU,NA)
Engine stop
Travel alarm
Swing shutoff
reverse(CX460to800, E805)
Boosting
High dump(CX700/800, E805)
Lift (LBX-MH)
Hyd Fan reverse
TR4 0 0 0 0
Fuel supply pump
(EU)
X
X
Drop (LBX-MH)
X: Not used
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-63

SW1 to SW3
CHK
MODE II H
SW4
0000
SW4 to SW7
3
SW1
0000
SW5
0000
SW2
0000
SW6
0000
SW3
0100
SW7
0000
Controller switch input (sensor switch)

Controller switch input (operation
switch)
Pressure switch electronic control box switch inputs: 0 = OFF; 1 = ON

SW1 0 0 0 0
SW2 0 0 0 0
SW3 0 0 0 0
Attachment press. SW
Air cleaner
Battery charge
Travel press. SW
Coolant SW
Engine stop
Swing press. SW
2nd auxiliary press. SW
Drop (LBX-MH)
Auxiliary pressure SW
Boom up press. SW
Lift (LBX-MH)
SW4 0 0 0 0
SW5 0 0 0 0
Soft/hard (EU, NA)
SW6 0 0 0 0
Swing lock
Windshield washer
Alarm change
Free swing (NA)
Emergency stop
(EU, NA)
High dump (CX700/800, E805)
Working lamp
Breaker mode
One-touch idle
Wiper
L/M mode
SW7 0 0 0 0
Anti-theft protection
Key switch
Fan reverse(CX460 to
800; E805)
X
X = Not used

CHK
MODE I H
TG
0000
rpm
BP
0000
MPa
()
FS
0080
AC
0005
SP1
0000
TR5
0010
SP2
0000
FS:
AC:
TR5:
TG:
BP:
AC
SP1
SP2
Fuel sensor resistance

A/C control temperature
Engine oil pressure
Target engine speed
Boom bottom pressure (Europe only)
Overload alarm pressure display (only when beacon switch ON)
Atmospheric pressure
Boost pressure
0 0 0 4
1: below 30C
2: between 30C and 45C
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-64
Setting of unit fir each shipping territory
NOTE: Below a decimal point is not displayed but it is

as fallows.
TR5, SP1, SP2

Default
When switched
Japan
kPa
kgf/cm2
Export
kgf/cm2
kPa
North America
psi
kPa
Europe
kPa
.
.
.
kPa
kgf/cm2
psi
800.1.04.04.08D

CHK
MODE II H
TR1
0001
R
FT
TV
5
R
0080
TR2
0001
TR1
FT
0000
TR3
0000
TR2
TV
0100
TR4
0000
1. While the travel mode switch is ON on the CHK2

screen, the output status when over-current has
been detected in the past is displayed.
TR3
TR4
Engine load ratio

Fuel temperature
Transistor output status when over-current
detected
detected
detected
detected
2. Data is cleared by resetting the trouble code on the

trouble diagnosis screen.
3. The example in the figure above shows that a travel
alarm, swing braking, and battery relay output were
being carried out when over-current was detected.

CHK
MODE II H
TR1
0010
6
R
0080
TR2
0000
FT
0040
TR3
0000
TV
0100
TR4
0000
TR3
TR4
Results of automatic short detection

4. This data is cleared when the key switch is switched

OFF.
* For CHK1 to 6, the units can be switched with the
work lamp switch. Status held as is when key OFF
1. Shorts are automatically detected if the key switch

is switched ON while the one-touch idle switch is
ON.(* The engine must not be running.)
2. If you switch to the CHK2 screen and switch the
travel mode switch ON for 10 seconds, the automatic detection results are displayed.
3. The example in the figure above shows that the 2speed travel line is currently shorted.
R
FT
TV
TR1
TR2
Engine load ratio

Fuel temperature
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-65
Diagnostic code
2. Detection of engine failures DIAG1 to 6
1) Trouble diagnosis (DIAG1), Engine system current trouble status (trouble code)
DIAG
MODE II H
0000
0118
0000
0000
0000
0000
0000
E:
Example
Engine system trouble code

For the engine error code list, refer to Page
68
Water temperature sensor abnormality
2) Trouble diagnosis (DIAG2), Engine system past trouble status (trouble code)
DIAG
MODE II H
0000
2106
0000
0000
0000
0000
0000
E:
Example
Engine system trouble code

CAN time-out abnormality
3) Trouble diagnosis (DIAG2), Engine system past trouble status (time of trouble: controller hour meter value)
E:
DIAG
MODE II H
0000
Example
3
E
0200
0000
0000
0000
0000
0000
1. Switching the work mode switch ON for longer than

10 seconds clears the data on past trouble codes
and their times of occurrence.
2. The time displayed with DIAG3 is the time at
which the first trouble code occurred after the data
was cleared. (The times for the second and subsequent trouble codes are not recorded.)
3.
Lep SC4604001-0EN
Engine system trouble code trouble code.

CAN time-out abnormality: Abnormality
occurred at 200 hours
When the data is cleared, the DIAG2 and

DIAG3 data is stored into EEPROM.
Issued 03-07
Copyright
4001-66
4) Trouble diagnosis (DIAG5), Machine main unit system Current trouble status (trouble code)
DIAG
MODE II H
0000
0020
0000
0000
0000
0000
0000
M:
Example
Machine main unit system trouble code

Oil temperature sensor abnormality
M0000:
M0010:
M0020:
M0030:
M0040:
M0050:
M0060:
M0070:
M0080:
M0090:
M00A0:
M00B0:
M00C0:
M00F0
M00F1
M00F2
M00F3
M00F4
M00F5
No defect
Transistor output short
Oil temperature sensor
Fuel surface sensor
Pressure sensor (P1)
Pressure sensor (P2)
Pressure sensor (N)
Key switch
Pressure switch (attachments or travel)
CAN communications error
Controller reset
Engine controller mismatch
Boom pressure sensor (Europe)
Overheat (at cooling water temperature of over 105C (221F)
Engine oil pressure drop (at pressure of below 40kPa
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-67
5) Trouble diagnosis (DIAG5), Machine main unit system Past trouble status (trouble code)
M:
DIAG
MODE II H
0000
Example
5
M
0020
0000
0030
0000
0000
0000

Oil temperature sensor abnormality, fuel sensor abnormality
6) Trouble diagnosis (DIAG6), Machine main unit system Past trouble status (time of trouble: controller hour
meter value)
M:
DIAG
MODE II H
0000
Example
M
2000
0000
1000
0000
0000
0000

Oil temperature sensor abnormality: Abnormality occurred at 2000 hours
Fuel sensor abnormality: Abnormality
occurred at 1000 hours
1. Switching the work mode switch ON for longer than

10 seconds clears the data on past trouble codes
and their times of occurrence.
2. The time displayed with DIAG6 is the time at
which the first trouble code occurred after the datawas cleared. (The times for the second and subsequent trouble codes are not recorded.)
3.
Lep SC4604001-0EN
When the data is cleared, the DIAG5 and

DIAG6 data is stored into EEPROM.
Issued 03-07
Copyright
4001-68
7) Engine error code list
Engine Type
Trouble
code
Trouble contents
4H
6H
6U/
6W
Monitor display
Restoration from
troubles
0087
No pump pressure send (fuel leak)
ELEC PROBLEM
0088
Common rail pressure abnormality

(1st stage. 2nd stage)
ELEC PROBLEM
0089
Common rail pressure abnormality

(pump overpressure send)
ELEC PROBLEM
0090
SCV drive system cut line, +B short, ground

short
PCV1 drive system cut line or ground snort
ELEC PROBLEM
0092
PCV1 drive system +B short
--
--
ELEC PROBLEM
0107
Atmospheric pressure sensor abnormality

(low voltage abnormality)
ELEC PROBLEM
0108
Atmospheric pressure sensor abnormality

(high voltage abnormality)
ELEC PROBLEM
0112*
Intake air temperature sensor abnormality

ELEC PROBLEM
0113*
Intake air temperature sensor abnormality

ELEC PROBLEM
0117*

ELEC PROBLEM
0118*

ELEC PROBLEM
0182*
Fuel temperature sensor abnormality

--
0183*
Fuel temperature sensor abnormality

--
0192
Common rail pressure sensor abnormality

ELEC PROBLEM
0193
Common rail sensor abnormality

ELEC PROBLEM
0201
Injection nozzle #1 drive system open line
ELEC PROBLEM
0202
ELEC PROBLEM
0203
ELEC PROBLEM
0204
ELEC PROBLEM
0205
--
ELEC PROBLEM
0206
--
ELEC PROBLEM
0219
Overrun
ELEC PROBLEM
0237
Boost pressure sensor abnormality

ELEC PROBLEM
0238
Boost pressure sensor abnormality

(nigh voltage abnormality)
ELEC PROBLEM
0335/
0336
Crank sensor abnormality

(no signal, abnormal signal)
ELEC PROBLEM
0340/
0341
Cam (G) sensor abnormality

(no signal, abnormal signal)
ELEC PROBLEM
0380
Glow relay abnormality
ELEC PROBLEM
0487
EGR position sensor abnormality
ELEC PROBLEM
0488
EGR valve control abnormality
ELEC PROBLEM
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-69
Engine Type
Trouble
code
1
2
Trouble contents
4H
6H
6U/
6W
Monitor display
Restoration from
troubles
0522
Engine oil pressure sensor abnormality

ELEC PROBLEM
0523
Engine oil pressure sensor abnormality

ELEC PROBLEM
0601
ROM abnormality
ELEC PROBLEM
0603
EEPROM abnormality
ELEC PROBLEM
0606
CPU abnormality
ELEC PROBLEM
0611
Charge circuit 1 abnormality
ELEC PROBLEM
0612
Charge circuit 2 abnormality
ELEC PROBLEM
1093
No pump pressure send (2nd stage)
--
--
ELEC PROBLEM
1095
Pressure limiter open
ELEC PROBLEM
1112*
Boost temperature sensor abnormality

--
1113*
Boost temperature sensor abnormality

--
1173
Overheating
--
1261
Injection nozzle common 1 drive system

abnormality
ELEC PROBLEM
1262
Injection nozzle common 2 drive system

abnormality
ELEC PROBLEM
1291
PCV2 drive system cut line or ground short
--
--
ELEC PROBLEM
1292
PCV2 drive system +B short
--
--
ELEC PROBLEM
1345
Cam (G) sensor out of phase
ELEC PROBLEM
1625
Main relay system abnormality
ELEC PROBLEM
1630
A/D conversion abnormality
ELEC PROBLEM
1631
5V power supply 1 voltage abnormality
--
1632
ELEC PROBLEM
1633
ELEC PROBLEM
1634
ELEC PROBLEM
1635
ELEC PROBLEM
2104
CAN bus abnormality
ELEC PROBLEM
2106
CAN time-out abnormality
ELEC PROBLEM
Item marked with O in the table means that it can be applied.

Restoration from troubles.
There are 2 ways as illustrated below to restore it from troubles.
In order to clear an error code depending on circumstances, control of main switch is necessary as follows:
1) Turn ON the key switch to start the engine, hold the switch for 10 second as it is turned ON, and then turn it OFF
to restore it to be normal.
2) Turn ON the key switch, hold the switch for 10 second as it is, and then turn it OFF to restore it to be normal
For temperature sensors marked with * in the table however, hold the key switch for 3 minutes after it has been
turned ON, then turned it OFF.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-70
Machine history
1. Screen HR1
ENG
WRK
U
T
S
PU
BRK
: Hour meter (alternator generation time)

: Machine operation time (attachment ON or travel
ON)
: Attachment operation time
: Travel operation time
: Swing operation time
: Boost time
: Breaker usage time
H
S
L
A
WT
OT
FT
: H mode usage time

: S mode usage time
: L mode usage time
: A mode usage time
: Maximum coolant temperature
: Maximum hydraulic oil temperature
: Maximum fuel temperature
1
2
3
4
5
: Controller power supply ON time

: 1-speed mode usage time
: 2-speed mode usage time
: Travel hydraulic only time
: Maintenance time
: *****
: *****
2. Screen HR2
3. Screen HR3
4. Screen HR4
[P1 pressure distribution]
1
: Time P1 10 MPa or less
2
: Time P1 10 to 15 MPa
3
4
5
6
7
: Time P1 35 MPa
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-71
5. Screen HR5
[P2 pressure distribution]
1
: Time P2 10 MPa or less
2
3
4
5
6
7
: Time P2-35 MPa
6. Screen HR6
[Engine speed distribution]
1
: Time N 1175 min-1 or less
2
: Time N 1175 to 1375 min-1
3
: Time N 1375 to 1575 min-1
4
: Time N 1575 to 1775 min-1
5
: Time N 1775 to 1975 min-1
6
: Time N 1975 to 2175 min-1
7
: Time N 2175 min-1 or more
7. Screen HR7
[Coolant temperature distribution]
1
: Time TW 77C or less (Marks 1 and 2 on the bar
graph)
2
: Time TW 77 to 82C (Mark 3 on the bar graph)
3
4
5
6
7
: Time TW 105C or more (Mark 8 on the bar graph)
8. Screen HR8
[Hydraulic Oil temperature distribution]
1
: Time TO 45C or less (Marks 1 and 2 on the bar
graph)
2
: Time TO 45 to 60C (Mark 3 on the bar graph)
3
4
5
6
7
: Time TO 98C or more (Mark 8 on the bar graph)
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-72
9. Screen HR9
[Fuel temperature distribution]
1
: Time TF 30C or less
2
: Time TF 30 to 40C
3
: Time TF 40 to 50C
4
: Time TF 50 to 60C
5
: Time TF 60 to 70C
6
: Time TF 70 to 80C
7
: Time TF 80C or more
10. Screen HR10

[Load ratio distribution]
1
: Time R 30% or less
2
: Time R 30 to 40%
3
: Time R 40 to 50%
4
: Time R 50 to 60%
5
: Time R 60 to 70%
6
: Time R 70 to 80%
7
: Time R 80% or more
11. Screen HR11

[H mode high idle load ratio distribution]
1
2
: Time R 30 to 40%
3
: Time R 40 to 50%
4
: Time R 50 to 60%
5
: Time R 60 to 70%
6
: Time R 70 to 80%
7
12. Screen HR12

[S mode high idle load ratio distribution]
1
2
: Time R 30 to 40%
3
: Time R 40 to 50%
4
: Time R 50 to 60%
5
: Time R 60 to 70%
6
: Time R 70 to 80%
7
Switching any of the work mode switches for the HR1 to 12 display ON for longer than 10 seconds clears all the
usage history data.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-73
Resetting
Resetting (RST1, 2)
MODE
BRK
L/M
AI
PA
AU
HLD
OUT
: Travel mode, work mode

: Breaker engine speed set
: Lifting magnet engine speed set
: Auto idle time set (1 to 30 sec.)
: Pump output adjustment
: Automatic boost rise
: Engine protection function
: Previous data hold set
: Oil pressure drive fan inspection mode
1) Breaker speed set
1
2
3
4
Select the breaker speed set (BRK) with the Buzzer Stop switch. (The selected item switches from light-on-dark
display to dark-on-light display.)
Now, set the breaker speed (BRK) to 1800 min-1. While watching the monitor, adjust the engine speed with the
throttle volume. When the adjustment is complete, turn ON the work mode switch for 10 seconds. Buzzer sound to
indicate that the settings have been memorized.
Switch OFF the key switch.
To check, see the CHK1 engine speed.
2) Lifting magnet speed set
1
2
3
4
Select the lifting magnet speed set (L/M) with the buzzer stop switch. (The selected item switches from light-ondark display to dark-on-light display.)
Now, set the lifting magnet speed (BRK) to 2000 min-1. While watching the monitor, adjust the engine speed with
the throttle volume. When the adjustment is complete, turn ON the work mode switch for 10 seconds. Buzzer
sound to indicate that the settings have been memorized.
To check, see the CHK1 engine speed.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-74
3) Auto idle time change
1
2
Select the auto idle time change (AI) with the buzzer stop switch. (The selected item switches from light-on-dark
Now, set the auto idle time to 10 seconds. Turn ON the travel mode switch untl the number reaches 10. The
number increases each time the switch is switched ON and can be set from 1 to 30. When the setting is complete,
turn ON the work mode switch for 10 seconds. Buzzer sound to indicate that the settings have been memorized.
Turn OFF the key switch.
4) Pump output change

PA=0000
PA=0001
PA=0002
PA=0003
:
:
:
:
Normal output mode

Low output mode 1 (-100 mA)
Select the pump output adjustment (PA) with the buzzer stop switch. (The selected item switches from light-ondark display to dark-on-light display.)
2 Now, set the pump output to low-output mode. Turn ON the travel mode switch so that the number reaches 1, 2, or
3. Each time the switch is switched ON, the number displayed moves to the next step in the sequence 0, 1, 2, 3,
When the setting is complete, turn ON the work mode switch for 10 seconds. Buzzer sounds to indicate that
the settings have been memorized.
3 Switch OFF the Key switch.
5) Automatic pressure rise release setting

AU 0 0 0 0
Automabic boost rise (0=ON, 1=OFF)
Engine protection function (0=ON, 1=OFF)
*****
*****
1
2
Select the automatic boost rise release and engine protection function release (AU) with the buzzer stop switch.
(The selected item switches from light-on-dark display to dark-on-light display.)
Now, set the automatic boost rise engine protection fanction to none. Turn ON the travel mode switch so that the
number reaches 1. Each time the switch is switched ON, the number displayed moves to the next step in the
sequence: 0000 ->0001 ->0010 ->0011 ->0000. When the setting is complete, turn ON the work mode switch for
10 seconds. Buzzuer sounds to indicate that the setteings have been memorized.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-75
6) Previous data hold condition change
Auto mode (0 = default setting, 1 = previous data held)

Work mode (0 = default setting, 1 = previous data held)
Travel mode (0 = default setting, 1 = previous data held)
*****
1
2
Select the previous data hold (HLD) with the buzzer stop switch. (The selected item switches from light-on-dark
Now, set the work mode to previous data hold.
Switch the travel mode switch ON so that the number reaches 1.
Each time the switch is switched ON, the number displayed moves to the next step in the sequence:
0000
0001
0010
0011
0100
0101
0110
0111
1000
1001
1010
1011
1100
1101
1110
1111
700-1-04-04-07BJ2
When the setting is complete, switch the work mode switch ON for 10 seconds. The buzzer buzzes to announce
that the storing the setting into memory is complete.
7) Hydraulic drive fan inspection mode (only for specifications with hydraulic drive fan)
1
2
Select the previous data hold (OUT) with the buzzer stop switch. (The selected item switches from light-on-dark
The number displayed shows the command current value. The display immediately after the selection is the command current value. When the travel mode switch is turned ON once, the display becomes 0100 and each time
the switch is turned ON, the value displayed moves to the next step in the sequence:
->0100->0110->0120->0130->0140->0150->->0160->0170->0180->0190->0580->0590->0600-> Current value at present ->
3 For the hydraulic drive fan inspection mode, the previous time's data is reset. In other words, even if the key switch
is switched OFF with some current value set, the next time the Key switch is switched ON, the mode is normal
mode.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-76
8) Maintenance time setting
1
2
Move to RST2 with the buzzer stop switch and select (2). (The selected item switches from light-on-dark display to
dark-on-light display.)
The number displayed shows the time for displaying Maintenance time. The display immediately after the selection is the default maintenance time. Each time the travel mode switch is turned ON, the number displayed moves
one step through the cycle 0050->0250->0500-> 1000-> 2000-> 5000-> 0050-> 0250.
When the setting is complete, turn ON the work mode switch for 10 seconds. Buzzer sounds to indicate that the
settings have been memorised.
* If the buzzer stop switch is held ON for 20 seconds, the time until maintenance display (1) is reset.
9) Injector test mode
1
2
Move to RST2 with the buzzer stop switch and select (3). (The selected item switches from light-on-dark display to
dark-on-light display.)
Now, after the engine has been started, injector test mode is to be set here. Turn ON the travel mode switch so
that the number reaches 1. The number toggles between 0 and 1 each time you switch ON the switch.
When the number reaches 1, the engine speed is fixed at 500 min-1.
For the injector test mode, the previous time's data is reset. In other words, even if the key switch is turned OFF
with a value set, the next time the Key switch is turned ON, the mode is normal mode.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-77
MACHINE INFORMATION
Setting of machine model
The excavator model is selected after re initialising the
machine code or replacing an electronic control box.
1. Key switch ON, the screen below appears and ?
for machine is selected:
MACHINE: SH
TERRITORY:?
CONT. P / N
-4
MACHINE MODEL
SH0120
CX130
SH0150
CX160
SH0180
Not used
SH0200
CX210
SH0220
CX240
SH0250
CX290
SH0300
CX330
SH0400
CX460
SH0700
CX700
SH0800
CX800/E805
MACHINE: SH0300- 4
Lep SC4604001-0EN
T unit
EUROPE
MPa
Rest of world
KgF
5. Press the work mode switch. The screen below

appears and ? for language is selected.
MACHINE: SH0300- 4
TERRITORY: 3
CONT. P / N
LANGUAGE: ?
KHR3320
6. Press the travel mode switch to display the required

language code:
0 = Japanese
1 = English
2 = Thai
3 = Chinese
4 = German
5 = French
6 = Italian
7 = Spanish
8 = Portuguese
9 = Dutch
10 = Danish
11 = Norwegian
12 = Swedish
13 = Finnish
14 = Icons
MACHINE: SH0300- 4
KHR3320
MACHINE: SH0300- 4
CONT. P / N
Pressure
unit
LANGUAGE:?
3. Press the work mode switch. The screen below

appears and ? for territory is selected.
TERRITORY: ?
Destination
KHR3320
MACHINE CODE
CONT. P / N
Destination
code
LANGUAGE:?
2. Press the travel mode switch until the required

machine code is displayed.
TERRITORY:?
4. Press the travel mode switch until the required destination code is displayed.
LANGUAGE:?
TERRITORY: 3
CONT. P / N
LANGUAGE: 5
KHR3320
Example:
The screen above corresponds to a CX330 model
excavator for Europe in French.
KHR3320
Issued 03-07
Copyright
4001-78
7. After selecting the machine code, the destination
code and the language code, press the auto mode
switch and the screen below will appear:
10. To confirm the excavator model selection, press the

auto mode switch for 10 seconds:
The screen below will appear
MACHINE: SH0300- 4
TERRITORY: 3
LANGUAGE: 5
CONT. P / N
CS00F533
KHR3320
11. Press the auto mode switch again and the work
screen will appear:
Then the work screen is displayed:
CS00F521
CS00F521
8. If the machine code does not correspond to the

engine controller installed, the error code: E.
CONT. ERROR appears on the screen and the
audible warning device sounds.
MACHINE: SH0300- 4
TERRITORY: 3
12. Re-initialising the data

In the excavator model selection screen, if the auto
mode switch is pressed for 10 seconds, all the data
will be erased and the audible warning device will
sound.
If the key switch is turned OFF and then ON, the
screen below will appear and the procedure starts
again from the beginning.
LANGUAGE: 5
MACHINE: SH
CONT. P / N
-4
KHR3320
TERRITORY:?
LANGUAGE:?
E. CONT. ERROR
CONT. P / N
KHR3320
9. Check that the machine code corresponds to the

engine controller installed on the excavator.
- If the machine code is wrong, start the procedure
again from the beginning.
- If the engine controller installed is not correct,
change it.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-79
Changing the language code
Re-setting of engine information
Display the excavator model confirmation screen

(press the auto mode switch for 10 seconds).
To change the language code, press the travel mode
switch to display the required code.
To confirm the language code, press the work mode
switch and the audible warning device sounds.
Turn the key switch to OFF.
CHK
MODE
,S
0060
0089
4005
8008
0000
9543
0A79
800.1.04.04.08H
MACHINE: SH0300- 4
TERRITORY: 3
RST
MODE
LANGUAGE: 1
CONT. P / N
KHR3320
1
2
3
Example:
In the screen opposite, the language code has changed
from 5 (French) to 1 (English).
Display of engine information
Injector number
Selection places when entering ID code
a
i
q
b
j
r
c
k
s
d
l
t
4
5
6
7
e
m
u
w
f
n
v
x
g
o
0
0
h
p
0
0
Ab: Engine code

C to x: QR code
* 2 places of figure on the left both at the 6th and the
7th lines are fixed to 0.
Example:
CHK
MODE
,S
0060
0089
4005
8008
0000
9543
0A79
ID code
ID code
5 5 3 A 6 B1 8
361 F 3017
194 4 5200
0000
4F
800.1.04.04.08H
Example:
Engine controller (ECM) number
Engine serial number
Q adjustment number
898008-9543
604005
A79
Injector
Engine controller (ECM) number: A to J

* 2 places of figure on the left at the 1st line are fixed to
0.
1
2
3
0 0 A
C D E
G H I
B
F
J
Engine serial number: K to P

* 2 places of figure on the left at the 4th line are fixed to
0.
4
5
0 0 K L
M N O P
Q adjustment number: Q to S
* 1 place of figure on the left at the 7th line is fixed to 0.
7
800.1.04.04.08L-1
List of engine code-machine models applied.

ab
55
5B
63
Engine code
6HK1
6UZ1
6WG1
4
5
6
7
Machine models
CX330, CX350
CX460
CX700/800, E805
1st line
4th line
2nd line
5th line
3rd line
6th line
7th line
Q R S
800.1.04.04.08L-2
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-80
Selection of injector
(for checking ID code entered)
RST
MODE Hi ,S
11
6B18
553A
3017
361F
5200
1944
4F00
RST11
RST12
RST13
RST14
RST15
RST16
: Injector number 1
: Injector number 2
: Injector number 3
: Injector number 4
: Injector number 5
: Injector number 6
1 Select an injector number (RST11 ->RST12 . . . ->RST116) intending to check or enter with the buzzer stop switch.
2 The injector number on the fan side is assigned as 1 and the one on the pump side as 6 (refer to the figure below).
Fan
Engine
Pump
800.1.04.04.08K1
Remarks:
1
2
3
4
Engine information re-setting screen will appear from any service support screen by turning the one-touch idle
switch ON for more than 10 seconds.
Once you have entered the engine information re-setting screen, you cannot exit the screen until the key switch is
turned OFF.
While the engine is running, you cannot access the engine information re-setting screen even if the remarks "1"
above has been carried out.
Although the engine can be started while the engine information re-setting screen is being displayed, the ID code
cannot be entered.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-81
Entering injector ID code (after injector has been replaced)

RST
MODE Lo,S
11
6B18
553A
3017
361F
5200
1944
4F00
MODE Hi
MODE Lo
: Upper 2 places of figure on each line

: Lower 2 places of figure on each line
Injection ID code
800.1.04.04.08L.2
1 Select the replaced injector number 1 (RST11) with the buzzer stop switch.
2 Each time the auto mode switch is turned ON, 2 places of figure to be selected will shift in the order of "1Hi ->1Lo >2Hi -> 2Low -> 3Hi -> 3Lo -> 4Hi -> 4Lo -> 5Hi -> 5Lo -> 6Hi -> 7Hi -> 1Hi . . ." . (Selected line will change from
"light-on-dark" to "dark-on-light" indication.)
3 Keep on entering the ID code and enter lower 2 places of figure on 2nd line here. (At this time, the 2nd line is indicated "light-on-dark "and the mode shows "Lo".) For setting the upper place of 2 places, since the figure shifts in
the order of "0 -> 1 -> 2 . . . 9-> A -> B -> C -> D -> E -> F -> 0 . . ." each time the travel mode switch is turned ON,
select "1" here. For setting the lower place of 2 places, since the figure shifts in the order of "0 -> 1 -> 2 . . . 9 -> A
-> B -> C -> D -> E -> F -> 0 . . ." each time the travel mode switch is turned ON, select "F" here.
4 Check that any line does not indicate "light-on-dark " after completion of entering all ID codes by repeating steps 2)
and 3) above, then turn the work mode switch ON for more than 10 seconds to allow data communication with the
engine controller (ECM). The buzzer sounds when the data have been written correctly.
NOTE: The buzzer will not sound in case where any one of figures has been mistakenly entered. When the key is
turned OFF without sounding the buzzer, the ID codes already memorized remain unchanged.
5 Turn OFF the key switch.
6 Access the engine information setting screen again to check that the data have been rewritten correctly.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-82
Entering sheet of ID code of injector

Example:
Injection N 2
ID code
ID code
5 5 3 A 6 B1 8
361 F 3017
194 4 5200
0000
4F
800.1.04.04.080-3
Injection N 3
Injector
800.1.04.04.08L-1
Fan
Engine
Pump
800.1.04.04.080-4
Injection N 4
800.1.04.04.08K-1
Injection ID code
800.1.04.04.080-5
Injection N 5
800.1.04.04.08K-1
Injection N
800.1.04.04.080-6
Injection N 6
800.1.04.04.080-1
Injection N 1
800.1.04.04.080-7
800.1.04.04.080-2
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-83
TROUBLESHOOTING
Prior inspections
Item
Value
Action
---------------
Add fuel
Clean, drain
Fill with fluid
Drain, clean
Fill with oil
Fill with oil
Fill with coolant
-------
Tighten or replace
Tighten or replace
Tighten or replace
POINTS TO BE CHECKED WHEN STARTING

Lubricants - Coolants
1. Check the quantity of fuel
2. Check that fuel is not contaminated
3. Check the quantity of hydraulic fluid
4. Inspect the hydraulic fluid filter
5. Check the quantity of oil in each reduction gear
6. Check the quantity of engine oil
7. Check the quantity of coolant
Electrical equipment
8. Check the battery terminals and wiring for tightness and corrosion
9. Check the alternator terminals and wiring for tightness and corrosion
10. Check the starter motor terminals and wiring for tightness and
corrosion
OTHER POINTS TO CHECK
Hydraulic system - Mechanical equipment
11. Abnormal noise or smell
12. Check for oil leaks
13. Air in the system
-------
Repair
Repair
Bleed the air
Electrical system - Electrical equipment

14.
15.
16.
17.
18.
Check the battery voltage (with the engine shut down)

Check the quantity of fluid in the battery
Make sure that the cables are not discoloured, burnt or stripped
Check for missing or loose cable retaining clips
Check for damp on cables (especially on connectors and terminals)
19. Check fuses for condition and corrosion

20. Check the alternator voltage (with the engine speed above the
throttle mid-point) (when battery charge is insufficient, there can be
25 V only at start up)
21. Noise from relay battery (with starter motor ON or OFF)
Lep SC4604001-0EN
23-26 V
----------27.5-29.5 V
---
Replace
Add or replace
Replace
Repair
Disconnect and dry if damp
Replace
Replace
Replace
Issued 03-07
Copyright
4001-84
Reading the organisation charts

Error code and description of problem
The error code and the description of the problem are shown in the organisation charts.
Error code
Description of the problem
The message is still displayed even after refuelling
The message is still displayed even after adding coolant solution
Prior checks
Wire colour
Before identifying the cause of the problem, always

make prior checks.
When troubleshooting, refer to the table below for the

wire colours. (For connector numbers, refer to the following pages).
How to proceed
After checking or measuring the items described in one
step, depending on the results, choose YES or NO and
pass on to the next step.
The description in the YES or NO branches refers
directly to the cause of the problem as the result of
checks or measurements made. Refer to the description of the cause and carry out the repair procedures
described on the right-hand side.
The inspection methods/measurements are described
in one step. YES should be chosen if the criteria or
questions meet the situation; NO if they do not meet it.
The necessary preparation work, operating method and
the criteria are described under one step. This should
be carefully read before starting the inspection and the
measurements and the procedures should be followed,
starting with step (1) since negligent preparation work
or incorrect operating methods can cause damage to
the machine.
Lep SC4604001-0EN
Table showing wire colours

Symbol
Colour
Symbol
Colour
Black
Red
White
Yellow
Br
Brown
Lg
Light green
Pink
Sb
Sky blue
Violet
Blue
Green
Gr
Grey
Orange
BR indicates a wire of colour B striped with R.

Example: BR indicates a black wire with red stripes
IMPORTANT : Before removing or installing a connector, always turn the key switch OFF.
Issued 03-07
Copyright
4001-85
Procedures
1
This is how one has to proceed to detect defects when the message is still displayed after all necessary measures
have been taken to correct the error.
Message displayed
Fuel
Problem No.
The message is still displayed even after refilling the fuel tank.
Low coolant
The message is still displayed even after refilling with coolant solution.
Low oil press.
The message is still displayed even after adjusting the engine oil pressure
Overheating
The message is still displayed even when the hydraulic oil temperature
is 84C (183 F) or less and the engine coolant temperature is 92C
(197 F) or less.
Alternator
The message is still displayed.
Elect. problem
The message is still displayed.
This is how one has to proceed if the problem is not indicated by a message but machine operation is not correct.
A. Engine
YES
The engine does not

start.
ELEC. PROBLEM is shown on the monitor.
NO
Problem No.
6
7
Problem without message.

Impossible to change travel speed
Lep SC4604001-0EN
Problem No.
8
Issued 03-07
Copyright
4001-86
Fuel
Description of problem No. 1
- The message is still displayed even after refilling the fuel tank.
R5
A1
CONTROLLER
CN1
CN23
14
GL413
FUEL SENSOR
CNB3
9
GL413
BG660
KEY SWITCH OFF

700.1.04.06.11E
R5 Fuel sensor
Troubleshooting
Cause
Action
Key switch ON
Measure the fuel sensor resistance (R5)
using maintenance
support CHK4. (Refer
to the table below for
the resistance).
Replace the
Computer/concomputer/
troller (A1)
controller
defective
(A1)
YES
Key switch OFF

Disconnect the fuel sensor connector (R5) to
measure the resistance NO
on the connector at the
fuel sensor end. (Refer
to the table below for
the resistance).
NO
YES
Disconnect the CN23

connector to measure
the resistance between NO
GL female and the GND
earth. (Refer to the
table below for the
resistance).
YES
Disconnect connector
CN1 to measure the
resistance between GL
female and GND earth.
(Refer to the table
below for the resistance).
NO
Fuel sensor
(R5) defective
Replace or
check the fuel
sensor (R5)
Bad connection on fuel

sensor (R5)
Clean the
connection
terminal
Bad connection on CN23
Clean CN23
connection
terminal
Replace the
computer/
Defective comcontroller
puter (A1) or
(A1) or clean
incorrect CN1
the CN1 conconnection
nection terminal
YES
Note: All the bar-graph indicators are off when the circuit is open
Resistance between GL and BG

Monitor
1. Refill the tank
Resistance (OHM)
70-80
61-75
46-61
37-46
30-37
24-30
18-24
10-18
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-87
Add coolant solution

- The message is still displayed even after adding coolant solution.
CNB8
RESERVOIR 2
LEVEL SWITCH
GrG438
S56
BG642
CN4
CONTROLLER
CNB8
CN23
57
GrG437
RESERVOIR 1
LEVEL SWITCH
GrG437
S55
BG641
A1
700.1.04.06.11F2
S55 Reservoir tank low switch
S56 Reservoir tank low switch
Troubleshooting
Cause
Action
Key switch ON
Disconnect the minimum coolant solution level switch connector (S55) to see if the
message disappears
Defective minimum coolant

solution level
switch (S55)
YES
Short-circuit on
wire GrG
between the minRepair wire
imum coolant
GrG
solution level
switch (S55) and
CN23
YES
NO
Disconnect connector CN23 to

see if the message disappears
NO
Disconnect connector CN4 to

NO
Lep SC4604001-0EN
Replace the
minimum coolant solution
level switch
(S55)
YES
Short-circuit on
wire GrG
between CN23
and CN4
Repair wire
GrG
Defective computer/controller
(A1)
Replace the
computer/controller (A1)
Issued 03-07
Copyright
4001-88
Low engine oil pressure

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

Troubleshooting
Cause
Action
Oil pressure
switch (B21)
defective
Replace the
engine oil
pressure
switch (B21)
Short-circuit on
wire between
CNAO and
CNA2
Repair wire
Defective engine
controller (A2)
Replace
engine controller (A2)
Check the following points during the 12 seconds following starting the engine
Disconnect the engine oil pres- YES

sure switch connector (B21) to
NO
Disconnect connector CNAO

to see if the message disappears
NO
Lep SC4604001-0EN
YES
Issued 03-07
Copyright
4001-89
Overheating
- The message is still displayed even when the actual temperature is lower than the following:
Hydraulic oil temperature 98C (208F), engine coolant temperature 105C (221F).
Prior check:
1
Make sure that 8 bars are displayed on the hydraulic oil and engine coolant temperature gauge bar-graphs.
ENGINE CONTROLLER
CNA1
84
A2
CNA0
79
THERMO-SENSOR
(COOLANT)
CNA2
CONTROLLER
A1
WR484
BY498
11
CN1
CN23
CND3
10
OL415
13
11
BO425
B1
THERMO-SENSOR
(OIL)
B2
700.1.04.06.11H
Lep SC4604001-0EN

Issued 03-07
Copyright
4001-90
Troubleshooting
1
Cause
Action
Defective
coolant temperature sensor (B1)
Replace the
coolant temperature sensor (B1)
Bad connection on the

coolant temperature sensor connector
(B1)
Clean the
coolant temperature sensor
connecting
terminal (B1)
Bad connections on
CNAO, CNA1
or defective
controller
Replace controller or
clean CNAO,
CNA1 connector terminal
The 8 bars on the coolant temperature bar-graph are displayed.
Key switch ON
The temperature of the
coolant temperature
sensor (B1) is abnormal
compared to maintenance assistance CHK1 YES
(comparison between
the actual temperature
and the indicated temperature).
See coolant temperature in CHK1 WT.
Measure the actual
temperature
Check problem code
E0015 for the coolant
temperature sensor
(B1) with the maintenance diagnostic (DIAG
1)
YES
CNA2 on the coolant
temperature sensor
(B1) to measure the
resistance
YES
NO
Disconnect the connectors CNA1 and CNAO

NO
to measure the resistance between the male
terminals. (Refer to the
table below for the
resistance).
YES
Note: In the event of a short-circuit, the bar-graph goes off completely.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-91
Overheating (continued)
Troubleshooting
2
Cause
Action
The hydraulic temperature bar-graph displays 8 bars.
Key switch ON
The hydraulic oil temperature sensor (B2)
temperature is abnormal compared to mainYES
tenance assistance
CHK1 (comparison
between the actual temperature and that indicated).
See hydraulic oil temperature in CHK1 OT.
Measure the actual
temperature
See problem code
M0020 for the oil temperature sensor (B2)
using maintenance
diagnostic (DIAG 4)
YES
CND3 on the hydraulic
oil temperature sensor NO
(B2) to measure the
resistance. (Refer to the
table below for the
resistance).
YES
Disconnect the CN23

connector to measure
the resistance between
the male terminals OL
and BO. (Refer to the
table below for the
resistance).
YES
NO
CN1 to measure the
resistance between the
female terminals OL
and BO. (Refer to the
table below for the
resistance).
YES
NO
Defective
hydraulic oil
temperature
sensor (B2)
Replace the
hydraulic oil
temperature
sensor (B2)
Bad connection on the

hydraulic oil
temperature
sensor connector (B2)
Clean the
hydraulic oil
temperature
sensor connecting terminal (B2)
Bad connections on
CN23
Clean the
connecting
terminal on
CN23
Defective
computer/
controller
(A1) or bad
connection
on CN1
Replace the
computer/
controller
(A1) or clean
the connecting terminals
on CN1
Note: In the event of a short-circuit, the bar-graph goes off completely.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-92
Coolant and hydraulic oil temperature sensor resistance

NOTE: The resistance varies with temperature.
Coolant or hydraulic oil
temperature
Coolant temperature sensor (B1)
Hydraulic oil temperature

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

- The message is still displayed.
CN13
S1
19
P5
KEY SWITCH
K7
G2
ALTERNATOR
LgR540
BATTERY RELAY
HOUR METER
CNC9
CN22
2
A1
LgR540
LgR542
ENGINE
CONTROLLER
B
R
G020
SG
CN26
CN1
CONTROLLER
LgR540
BrR544
BrW545
A2
BrR030
M1
BrR543
STARTER
700.1.04.06.11J2
A1
A2
G2
K7
Computer/controller
Engine controller
Alternator
Relay battery
Lep SC4604001-0EN
M1 Starter motor
P5 Hourmeter
S1 Key switch
Issued 03-07
Copyright
4001-93
Troubleshooting
NO
The hour meter (P5)
does not work
YES
Cause
CN1 to measure the voltage between the female
terminal on wire WR and
Ground. 10V or above.
NO
Action
Break in wire between

CN1 and CN22
Repair wire
Bad connection on CN1

or defective controller
Clean CN1 connector

terminal or replace controller
Defective alternator (G2)
Replace the alternator

(G2)
Break in wire between

CN22 and alternator or
bad connection on alternator connector terminal
of alternator
Repair wire between

CN22 and alternator or
clean the connector
YES
Disconnect the connector CNC9 on alternator R terminal to measure the voltage between alternator
NO
side and ground. 10 V or above.
YES
CN22 to measure the
voltage between the
male terminal on wire
LgR and ground. 10 V or
above
NO
YES
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-94
Electrical system troubleshooting

- The message is still displayed
TRAVEL ALARM
K32
K5
HYDRAULIC
FAN RELAY
CN.5
CONTROLLER
VR
YR
5
1
2
3
4
1
24VB
REFUEL PUMP
FREE SWING/BEACON
WARNING BUZZER
ENGINE STOP
HYD. FAN REVERSE
SWING BRAKE
2 SPEED TRAVEL
CUSHION
SWING SHUT-OFF
SPARE 1 (PNP)
SPARE 2 (PNP)
1
2
GW
B
1
2
GW
B
1
2
R
Y
HYDRAULIC
MOTOR (FAN)
SOLENOID
Y31
FREE SWING
SOLENOID
Y18
YW
CN22
RW
PW
2 STAGE RELIFE
1.25RW
1.25B
H2
BEACON
GrR
B
VR
CN.19
1
2
LR
PW
B
GrR
YR
RW
B
LIMIT SWITCH
(GATE)
2
1
BEACON RELAY
5
1
2
3
GR 4
S51
A1
W
0.85B
GR
OW
VW
W
OW
GW
W
WR
RW
VW
LW
LgW
OR
BrW
WL
WV
17
18
19
21
22
27
28
29
30
31
32
20
23
LW
LgW
OR
BrW
GW
YW
SOLENOID VALVE
0.85GR
OW
0.85VW
W
1
2
0.85VW
0.85B
1
2
LEVER LOCK
Y2
SWING BRAKE
Y3
(PINK TAPE)
0.85LW
0.85LgW
1
3
6
4
5
2
0.85GR
0.85B
(BLUE TAPE)
0.85LW
0.85B
0.85BrW
GW
0.85YW
1
2
2 SPEED TRAVEL
Y4
2 STAGE RELIEF
Y5
(RED TAPE)
0.85YW
0.85B
1
2
(YELLOW TAPE)
CN24
0.85LgW
0.85B
WR
CN.23
1
2
SOFT/HARD
Y6
(LIGHT GREEN TAPE)
16
CN.6
1
2
6
8
9
7
CONNECTOR
(OPTION)
0.85BrW
0.85B
1
2
SWING SHUT-OFF
Y1
WR
(GREEN TAPE)
IS-ENGINE
STOP SWITCH
47
CN.A0
A2
OPTION (REFUEL PUMP)
REFUEL PUMP
RELAY
ENGINE CONTROLLER (ECM)
PUMP STOP
RELAY
S61
K31
AUTO / MANUAL
SELECT SWITCH
K30
4
1
2
5
3
4
1
2
5
3
2GrR
VR
B
2LR
L
OW
B
0.85BrR
VR
VR
GW
L
1
2
3
AUTO STOP
ALARM
B82
0.85BrR
0.85B
M14
OW
1
3
2
2GrR
OW
2B
2LR
2B
1
2
2R
2B
REFUEL PUMP
700.1.04.06.11KA
A1 Computer
A2
B82
H2
K5
K30
K31
K32
M14
S51
Engine controller
Refuel pump stop alarm
Travel alarm (North America)
Relay-rotary light
Refuel pump relay
Refuel pump stop relay
Relay, hydraulic fan
Fuel feed pump motor
Lep SC4604001-0EN
S61
Y1
Y2
Y3
Y4
Y5
Y6
Y18
Y31
Refuel pump switch

Swing pilot shut-off solenoid valve (green band)
Pilot pressure solenoid valve (blue band)
Swing brake solenoid valve (pink band)
Power-up solenoid valve
Cushion control solenoid valve (light green band)
Free swing solenoid valve (North America)
Cooling hydraulic motor solenoid valve
Issued 03-07
Copyright
4001-95
Troubleshooting
Cause
Action
Troubleshooting using the diagnostic system

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

YES
The failure code disappears after disconnecting the solenoid valve
connector
YES
Defective (Yn) solenoid

valve
Replace the solenoid

valve (Yn)
Short-circuit on wire
Repair the wiring
Defective controller
Replace controller
NO
The failure code disappears when either one of connectors CN21,
CN22, CN23 in short-circuit line is disconnected
YES
NO
The failure code disappears after disconnecting connector CN6
YES
NO
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-96
ELECTRICAL INSPECTION OF COMPONENTS

Details of service connector kit
(380050017)
0.85
BW
0.85
WY
02A
0.85
WL
01A
0.85BW
50
01A
50
50
50
BrG
BrG
200
50
03A
0.85WY
100
BrG
50
100 101
02A
150
100
0.85
WY
0.85
BW
01B
0.85
WL
02B
03A
03B
0.85WL
BrB
150
100
700.1.04.02.14AH
700.1.04.02.14AA
8. For pressure sensor (3P)
1. For solenoid valve and fuel sensor
0.85YL
200
50
01A 02A 03A
50
BrB
50
102 103
100
0.85 0.85 0.85

YL BY Y
150
50
BrG
50
BrB
102
01A
50
0.85BY
02A
BrG
150
103
03B 02B 01B

03A
0.85 0.85 0.85

BY YL
Y
0.85Y
700.1.04.02.14AB
2. For electromagnetic proportional valve of hydraulic

pump
700.1.04.02.14AI
9. For atmospheric pressure sensor
BrG
BrG
BrB
104 105
0.85BO
01A
104
50
100
150
50
BrB
150
0.85BO
300
50
01A 02A
50
0.85OL
105
02A
700.1.04.02.14AC
3. For electromagnetic proportional valve of hydraulic

pump
0.85OL
700.1.04.02.14AJ
10. For intake air temperature sensor
L
L
106 107
1.25YG
106
BY
50
100
01A
150
50
BY
150
1.25 1.25
YG BY
01A 02A
1.25 1.25
BY Y
02A 01B
600
50
50
50
107
700.1.04.02.14AD
4. For pressure switch
01B
1.25Y
700.1.04.02.14AK
BY
BY
108
108 109
50
100
150
11. For electromagnetic proportional valve of controlling fan speed (2P)
150
1.25RW
109
01A
50
700.1.04.02.14AE
5. For the harness side of pressure switch
50
01A 02A
1.25RW
800
50
1.25B
C
C
814 850
02A
814
50
100
1.25B
150
700.1.04.02.14AL
150
12. For fan reversing solenoid valve (2P)
450
3B
700.1.04.02.14AF
01A
6. For receiver dryer (2P)
6
50
0.85BP
02A 01A
0.85BP
50
3B
01A
150
3LR
02A
50
02A
0.85PL
700.1.04.02.14AG
Lep SC4604001-0EN
6
02A
50
7. For oil temperature sensor
200
50
01A
50
0.85PL
50
3LR
700.1.04.02.14AM
13. For glow (1P)
Issued 03-07
Copyright
4001-97
700.1.04.02.14AN
14. For fuel pump (6P)

700.1.04.02.14AP
16. For injector (12P)
700.1.04.02.14AO
15. EGR (8P)

700.1.04.02.14AQ
17. For sensor (20P)
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-98
Details of service connector kit (380350031) for breaker from engine controller (ECM) to main
harness assembly
Engine controller C-2
Engine controller C-1
700.1.04.02.21P
1. For ECM-terminal
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-99
Engine controller (ECM)
700.1.04.02.21Q
2. For Main-terminal
1.250
001
50
150
50
1.250
001
50
1.250
002
700.1.04.02.21R
3. For Joint-terminal
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-100
Main pump proportional solenoid
6 solenoid valve bank

1. Disconnect connector (A) from one of the solenoids
on the 6 solenoid valve bank (52)
1
Y5
Y1
Y4
Y7
Y2
Y6
700.1.04.02.21UA
1. Disconnect connector (1) from the main pump

hydraulic solenoid (Y7).
Y3
52
5
A
3
CD00F023
Marking
CS00E534
2. Connect the appropriate service connector (2P) (4)

between the connector at the pump end (2) and the
connector at the main harness end (3) and install the
voltmeter (5).
NOTE: The + terminal of the voltmeter should be connected to wire BrB (brown/black) on the service connector coming from the main harness and the - terminal
to wire BrB (brown/black) on the service connector
coming from the hydraulic pump.
3. When the connections have been made, start the
engine and check the current on the voltmeter (5) in
each work mode, at maximum speed.
Function
Y1
Swing pilot shut-off solenoid valve (green band)
Y2
Y3
Y4
Y5
Power-up solenoid valve (yellow band)
Y6
Not used (light green band)
Yn
3
Current in mA
H
Maxi
Min
Maxi
Min
490
240
405
240
<50
Auto
S
490
490
1
CS99A843
2. Connect the appropriate service connector (2P)(3) to

the connector on the disconnected solenoid (1) only
(Yn) and install the voltmeter (2).
3. When the connection has been made, the solenoid
resistance reading on the voltmeter (2) should be 45
at 20C (68 F).
NOTE: The resistance value varies with temperature.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-101
Hydraulic oil temperature sensor
B2
3. When the connection has been made, place the temperature sensor (B2) in the beaker (5) containing
water. Place the beaker (5) on the tripod (7). Using the
spirit lamp (8) gradually increase the water temperature in the beaker (5). Using the voltmeter (9), check
the resistance value in function of the temperature
read on the thermometer (4) (see table below).
Oil Temperature
Oil temperature sensor
20C (68F)
2.45 k
30C (86F)
1.66 k
40C (104F)
1.15 k
50C (122F)
0.81 k
60C (140F)
0.58 k
70C (158F)
0.43 k
80C (176F)
0.32 k
Pressure sensor
700.1.04.02.21AB
B42
1. Remove the oil temperature sensor (B2) from the

machine.
B44
3
4
5
9
6
700.104.02.21AD1
7
8
CS99A851
3
4
5
6
7
8
9
Service connector (2P)

Thermometer
Beaker
Temperature sensor (B2)
Tripod
Spirit lamp
Voltmeter
B43
2. Connect the appropriate service connector (2P) (3) to

the temperature sensor (B2) connector (1) or (2) and
install the voltmeter (9).
700.1.04.02.21AB1
B42 Pressure sensor P1

B43 Pressure sensor (nega-cont.) (N)
B44 Pressure sensor P2
1. Disconnect the connector from the main hydraulic
pump pressure sensor.
Lep SC4604001-0EN
Issued 03-07
Copyright
4001-102
(psi) (MPa)
(7252)
(725)
(580)
B42
4
B43
(435)
(290)
B44
(145)
Pressure
Voltage (V)
700.1.04.02.21.AG
CS00E541
2. Connect the appropriate service connector (3P)(4)

between sensor (B42), (B43) or (B44) and the corresponding connector (1), (2) or (3) of the main harness
(5) and install the voltmeter (6).
NOTE: The + terminal on the voltmeter should be connected to wire YL (yellow/blue) on the service connector and the - terminal to the machine earth.
3. When the connection has been made, start the engine
and check the voltage read on the voltmeter (6) in
accordance with the pressures indicated in the table
below.
Pump pressure sensor (B42) and (B44)
Pressure (MPa)
Voltage (V)
50 (7252 psi)
4.5
43.7 (6338 psi)
37.5 (5439 psi)
25 (3626 psi)
17.5 (2538 psi)
0.5
Pressure sensor (nega-cont.) (B43)

Pressure (MPa)
Voltage (V)
5 (725 psi)
4.5
4.37(634 psi)
3.75 (544 psi)
2.50 (362 psi)
1.25 (181 psi)
0.5
NOTE: Formula for converting pressure:

1MPa = 1.019 x 10 kgf/cm2
Lep SC4604001-0EN
Issued 03-07
Copyright
4003
Section
4003
MAIN ELECTRONIC CONTROL BOX
ENGINE ELECTRONIC CONTROL BOX
CNH
Lep SM4604003-0EN

Printed in France
September 2007
Copyright
4003-2
TABLE OF CONTENTS
MAIN ELECTRONIC CONTROL BOX AND ENGINE ELECTRONIC CONTROL BOX ................................................. 3
Removal ...................................................................................................................................................................... 3
Main electronic control box ......................................................................................................................................... 3
Engine electronic control box ...................................................................................................................................... 4
Installation ................................................................................................................................................................... 4
Lep SM4604003-0EN
Issued 09-07
Copyright
4003-3
MAIN ELECTRONIC CONTROL BOX AND ENGINE ELECTRONIC

CONTROL BOX
Removal
STEP 4
STEP 1
B
A
CD00F011
JS00001A

STEP 2
Shut down the engine and position the starter switch on
OFF.
Remove the panel (A) located behind the operators

seat, taking care to disconnect the connector from the
cigarette lighter (B) and the solar radiation detector (C).
Main electronic control box

STEP 5
STEP 3
A
CD00F047
Disconnect the connectors CN1 to CN6 from the main

electronic control box (B).
Disconnect the main earth cable (-) (1) from the battery.
STEP 6
Remove the 4 retaining screws (A) from the main
electronic control box (B).
STEP 7
Remove the main electronic control box (B).
Lep SM4604003-0EN
Issued 09-07
Copyright
4003-4
Engine electronic control box

STEP 5
CNA1
K10
K11
K32
K6
K5
CNA0
Identify and remove the relay-rotary light (K5), the

relay-air conditioner condenser fan (K6), the relay,
hydraulic fan (K32), the relay-working light (cab) (K11)
and the relay-working light (upperstructure /attachment)
(K10).
STEP 6
Disconnect the connectors CNA0 and CNA1 from the
engine electronic control box (C).
STEP 7
Remove the retaining screws (D) from the engine
electronic control box (C).
STEP 8
Remove the engine electronic control box (C).
Installation
To install, proceed in the reverse order from that of
removal.
NOTE: To reprogram the main and engine electronic
control boxes, see Section 4001.
Lep SM4604003-0EN
Issued 09-07
5001
Copyright
Section
5001
OF THE TRACKS SET
CNH
Lep SM160B5001-0EN

Printed in France
May 2007
Copyright
5001-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
SPECIAL TORQUE SETTINGS..................................................................................................................................... 2
SPECIAL TOOLS ........................................................................................................................................................... 3
TRACKS SET................................................................................................................................................................. 4
Description ................................................................................................................................................................. 4
Removal ..................................................................................................................................................................... 5
Installation .................................................................................................................................................................. 8
Track tension adjustment ......................................................................................................................................... 10
Checking pin and bushing wear ............................................................................................................................... 12
WARNING: This symbol is used in this manual to indicate important safety messages. Every time you see this
symbol, read carefully the message that follows, as it indicates that there is a risk of serious injury.
SPECIFICATIONS
See Section 1002

See Section 1002
Lep SM160B5001-0EN
Issued 05-07
Copyright
5001-3
SPECIAL TOOLS
926407
1. Track removal hydraulic press CAS 10044

2. Loctite 262
3. Hammer
4. Lifting jib
5. Impact wrench
6. Torque spanner
7. Supports 10 T
8. Roller pump
9. Protractor attachment CAS 2162
Lep SM160B5001-0EN
Issued 05-07
Copyright
5001-4
TRACKS SET
Description
Lower mechanism
12
5
7
8
7
4
14
9
11
13
14
3
10
CI00E511
1
2
3
4
5
6
7
TRACK PAD
SCREW
NUT
END OF CHAIN PIN HALF-LINK
END OF CHAIN HALF-LINK
END OF CHAIN PIN
SHIM
Lep SM160B5001-0EN
8
9
10
11
12
13
14
END OF CHAIN PIN SPACER

RETAINER PIN
RH STANDARD TRACK PIN HALF-LINK
LH STANDARD TRACK PIN HALF-LINK
STANDARD TRACK PIN
STANDARD TRACK PIN SPACER
UNION
Issued 05-07
Copyright
5001-5
Removal
STEP 1
Park the machine on hard, flat ground. Rotate the
upperstructure of the machine so that the cab is over
the track to be removed.
STEP 2
JD00272A
Operate the machine until the main axle is close to the

centre of the sprocket. Operate machine to lower track
to be removed to ground. Rotate the upper structure of
the machine so that the cab is facing the front. Shut
down the engine.
STEP 4
JD00270A
Lower the bucket or the tool to lift the track a few

centimetres off the ground.
NOTE: If the machine does not have a bucket or tool
installed, install wood blocks under the dipper and
lower the dipper onto the wood blocks. Then, lower the
dipper to raise the machine.
STEP 3
JD00273A
Do not remove the non-return check valve. The grease

in the track adjustment cylinder is under high pressure.
Slacken the track by gradually loosening the non-return
check valve by about two turns. The grease will escape
from a port on the check valve thread.
JD00271A
The main axle (1) can be identified by flat surfaces on

one end and the pin (2) that fastens it at the other end.
Lep SM160B5001-0EN
WARNING: Grease is under heavy spring

pressure. Disassembly without releasing
pressure may result in serious injury or death.
Do not disassemble the track compensating
system before completely releasing the
grease pressure. Release grease pressure by
loosening check valve. Do not remove the
non-return check valve or retaining bracket.
Issued 05-07
Copyright
5001-6
STEP 5
STEP 7
JD00274A
JD00277A
Remove the four screws (1) and the track pad nuts on
top of the end of chain axle. Remove the track pad.
Remove the four screws and the nuts from the track
pad under the end of chain axle. Remove the track pad.
STEP 6
STEP 8
JD00275A
B504423M
Install a portable hydraulic press CAS 10044 on the

end of chain axle. Using the portable hydraulic press,
force the end of chain axle out.
STEP 9
Remove the portable hydraulic press.
JD00276A
Straighten up one end of the pin (1) and remove the pin
from the end of chain axle.
Lep SM160B5001-0EN
Issued 05-07
Copyright
5001-7
STEP 10
STEP 12
JD00278A
Using a crowbar, separate the chain links. Remove the

two spacers (1) from the end of chain axle.
STEP 11
JS00280A
Sling the lower end of the track. Start the engine.

Operate the machine backwards and move the dipper
out at the same time. When the track is free from the
sprocket, stop reversing the machine. Continue
operating the dipper out until the track is pulled from
beneath the machine. Stop the engine, move the track
to be replaced away from the machine.
JD00279A
Start the engine. Using the attachment, lift the

upperstructure on the side of the track to be removed.
Install supports under the machine to hold the machine
in place and lower the machine onto the supports. Shut
down the engine.
Lep SM160B5001-0EN
Issued 05-07
Copyright
5001-8
Installation
STEP 4
STEP 1
CD00F057
JD00279A
Lift the undercarriage. Install supports under the

machine to hold the machine in place.
Connect lifting equipment to the track. Lift the track on

the idler wheel.
STEP 5
STEP 2
JS00283A
JD00281A
Place and align the new track under the lower roller.
STEP 3
Sling the track to the attachment. Start the engine,

operate the machine forward and move the dipper out
at the same time to pull the track on the sprocket. Keep
the track engaged on the sprocket teeth.
Lower the machine onto the track chain.
Lep SM160B5001-0EN
Issued 05-07
Copyright
5001-9
STEP 6
STEP 9
B5573689M
JD00284A
Connect suitable pulling equipment to both ends of the

track chain. Operate the pulling equipment to pull both
ends of the track chain together.
Remove the portable hydraulic press. Install a new pin

(1) in the end of chain axle. Bend the ends of the pins
to brake the end of chain axle.
STEP 7
STEP 10
Install the two track pads, the screws and the nuts.
STEP 11
JD00278A
Install two spacers (1) in the two half links where the
end of chain axle is assembled.
STEP 8
B5171389M
Tighten the track pad screws to a torque (see the

specifications).
STEP 12
See "Track tension adjustment" in this section and
adjust the track tension.
B5491989M
Install the end of chain axle with the portable hydraulic

press CAS 10044.
Lep SM160B5001-0EN
Issued 05-07
Copyright
5001-10
Track tension adjustment
STEP 4
Check the tension of the tracks as required. Adjust the

tension for the type of surface the machine will be
operating on. Tighten the track for operation on hard
surfaces and loosen the track for operation on soft
surfaces.
Do the following procedure to increase the track

tension:
1. Clean the grease fitting of the track adjustment
cylinder.
STEP 1
Park the machine on hard, flat ground. Rotate the
upper structure of the machine so that the cab is over
the track to be checked.
STEP 2
JD00273A
2. Check that the check valve is tight.
JD00270A
Lower the attachment to lift the machine until the track

to be checked is lifted off the ground by a few
centimetres.
STEP 3
JD00287A
3. Inject grease into the track tension cylinder until the

required tension is obtained.
JD01074A
Measure the distance between the bottom surface of

the track frame and the top surface of the track shoe.
Compare the values with the specifications.
Lep SM160B5001-0EN
Issued 05-07
Copyright
5001-11
STEP 5
Do the following procedure to decrease the track
tension:
JD00273A
1. Do not remove the non-return check valve. Grease

in the track tension cylinder is under high pressure.
Release the track by gradually loosening the nonreturn check valve by about two turns, the grease
escapes from a port in the check valve thread.
WARNING: Grease is under havy spring

non-return check valve or retaining bracket.
2. When the track tension is correct, tighten the check

valve.
3. Clean the grease from the check valve.
Lep SM160B5001-0EN
Issued 05-07
Copyright
5001-12
Checking pin and bushing wear

The wear on the pins and bushings can be measured
with a micrometer or an outside calliper.
STEP 1
1
STEP 2
Measure the inside diameter of the bushing. Compare
the values with the specifications. Replace them if
necessary.
STEP 3
Measure the outer diameter of the track pin. Compare
necessary.
JS00288A
1
2
OUTSIDE CALLIPER
BUSHING
Measure the outer diameter of the bushing. Compare

necessary.
Lep SM160B5001-0EN
Issued 05-07
Copyright
5003
Section
5003
UPPER AND LOWER ROLLERS
CNH
Lep SM4605003-0EN

Printed in France
September 2007
Copyright
5003-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 3
SPECIAL TORQUE SETTINGS...................................................................................................................................... 3
SPECIAL TOOLS ............................................................................................................................................................ 3
LOWER ROLLER............................................................................................................................................................ 4
Description ................................................................................................................................................................. 4
Removal ..................................................................................................................................................................... 5
Reconditioning ........................................................................................................................................................... 6
Disassembly ............................................................................................................................................................... 6
Inspection ................................................................................................................................................................... 7
Assembly ................................................................................................................................................................... 7
Installation .................................................................................................................................................................. 9
UPPER ROLLER........................................................................................................................................................... 10
Description ............................................................................................................................................................... 10
Removal ................................................................................................................................................................... 11
Reconditioning ......................................................................................................................................................... 12
Disassembly ............................................................................................................................................................. 12
Inspection ................................................................................................................................................................. 14
Assembly ................................................................................................................................................................. 15
Installation ................................................................................................................................................................ 17
CHECKING FOR LEAKS .............................................................................................................................................. 18
symbol, carefully read the message that follows, as there is a risk of serious injury.
Lep SM4605003-0EN
Issued 09-07
Copyright
5003-3
SPECIFICATIONS
See Section 1002.

See Section 1002.
SPECIAL TOOLS
B407320M
Use CAS 1450 and CAS 1682 for the leak checks
shown below.
Lep SM4605003-0EN
Issued 09-07
Copyright
5003-4
LOWER ROLLER
Description
A
B
7
F
3
D
G
4
KTA1106Z-C02
1
2
3
4
LOWER ROLLER
DRAIN PLUG
WIRE CLIPS
END BEARING
5
6
7
8
FACE SEAL
SHAFT
O-RING
BUSHING
A.......................................................................................................................................................... 406 mm (15.88 in)

B........................................................................................................................................................... 318 mm (12.52 in)
C............................................................................................................................................................. 223 mm (8.78 in)
D......................................................................................................................................................... 200 mm (7.87 in)
E ............................................................................................................................................................... 36 mm (1.42 in)
F ............................................................................................................................................................. 170 mm (6.69 in)
G........................................................................................................................................................... 85 mm (3.35 in)
Lep SM4605003-0EN
Issued 09-07
Copyright
5003-5
Removal
STEP 5
STEP 1
Park the machine on hard, flat ground. Swing the
upperstructure of the machine so that the cab is over
the lower rollers to be removed.
STEP 2
1
JD01076A
At each end of the track, install wood blocks (1) under

the track.
STEP 6
JD00273A

Slacken the track by slowly loosening the non-return
check valve by about two turns, the grease will escape
from a port in the check valve thread.

non-return check valve or the retaining
bracket.
JD00299A
Install a wood block under the lower roller to support it.

Remove the screws and the retaining washers and
remove the lower roller.
STEP 3
Lower the attachment to lift the machine until a
sufficient gap between the track frame and the track is
obtained so that the lower roller can be removed.
STEP 4
1
JD01075A
Install supports (1) of suitable capacity under the

machine.
Lep SM4605003-0EN
Issued 09-07
Copyright
5003-6
Reconditioning
STEP 3
When the roller is worn out or is leaking, it must be

reconditioned or replaced by a new one. See Section
1002 for limits of wear.
4
5
Disassembly
STEP 1
1
JS00303A
Remove the face seals (5) from the end bearings (4)
with a screwdriver or similar tool. Be careful not to
damage the seal bore in the end bearing. Discard the
face seals.
STEP 4
000-6-04-0021B
Clean the lower roller (1) using a suitable solvent.

Remove the two drain plugs (2) and drain the oil.
STEP 2
7
7
3
3
6
1
JS00304A
Remove and discard the O-rings (7) from the shaft (6).
Remove the shaft (6) from the lower roller (1).
STEP 5
000-6-04-0021C
Remove the retainer rings (3) and the end caps (4) from
the shaft (6). Discard the retainer rings.
5
JS00305A
Remove and discard the face seals (5) from the lower
roller (1) or the shaft (6).
Lep SM4605003-0EN
Issued 09-07
Copyright
5003-7
Assembly
STEP 6
STEP 1
8
1
8
8
1
8
JS00306A
NOTE: Carry out this step only if inspection reveals that

the bushings (8) need to be replaced.
Using a hammer and a brass drift, drive the bushings
(8) out of the lower roller (1). Be careful not to damage
the seal bore in the lower roller. Discard bushings.
JS00309A
If the bushings (8) were removed, install new bushings

(8) in the lower roller (1) using a hydraulic press and an
appropriate centring piece.
STEP 2
Inspection
5
STEP 1
Clean all components with solvent.
STEP 2
Inspect the bushing surfaces on the shaft (6) for
scoring, pitting, and other damage. Measure the
diameter of the shaft at four opposing points. Compare
the values with the specifications, replace them if
necessary.
STEP 3
Inspect bushings (8) for wear and damage. Measure
the inner diameter and width of the bushing. Compare
the values with the specifications, replace them if
necessary.
1
JS00310A
Install an O-ring and a face seal metal bushing (5) in

the seal bore on each side of the lower roller.
STEP 4
Inspect the bore in each end bearing and in the lower
roller for damage that will result in leakage. Use new
parts as required.
Lep SM4605003-0EN
Issued 09-07
Copyright
5003-8
STEP 3
STEP 5
3
1
3
4
6
1
7
JS00311A
Apply clean grease on the shaft surface (6) and install

the shaft in the lower roller (1), lubricate and assemble
the O-rings (7) on the shaft (6).
STEP 4
4
000-6-04-0021C
Install the end caps (4) on the shaft (6) and install new
retainer rings (3).
NOTE: Check the adjustment settings of the face seal
covers as well as those of the retaining pitch holes, see
page 4.
STEP 6
See the chapter on leak checks, carry out an inspection
to ensure that the lower roller has been correctly
installed.
STEP 7
3
3
JS00312A
000-6-04-00-21M
Install the wire clips (3) using a hammer.
5
4
JS00313A
Install the O-ring and remaining face seal metal

bushings (5) in the seal bore of the end cap (4). Apply
clean oil copiously to the face seals (A).
Lep SM4605003-0EN
Issued 09-07
Copyright
5003-9
Installation
STEP 8
STEP 1
1
4
2
000-6-04-0021B
Fill the lower roller (1) with clean oil, see specifications.
Install the drain plug (2) in the end cap (4).
JD00316A
Align the lower roller in position under the lower

undercarriage.
STEP 2
JD00299A
Apply Loctite 262 to the screw threads. Assemble the

hardened washers and the screws.
STEP 3
Tighten the retaining screws of the lower roller end
bearings to torque (see Specifications). Remove the
wood blocks.
STEP 4
At each end of the track, remove the wood blocks from
beneath the track. Remove the two supports from
beneath the machine.
STEP 5
Refer to "Track tension setting" in Section 5001.
Lep SM4605003-0EN
Issued 09-07
Copyright
5003-10
UPPER ROLLER
Description
A
4
K
11
2
3
F
J
6
9 10
300.6.03.01.08ABIS
1
2
3
4
5
6
UPPER ROLLER
OIL DRAIN PLUG
SCREW
COVER
SEAL
THRUST PLATE
7
8
9
10
11
SHAFT
FACE SEAL
BUSHING
BUSHING
BRACKET
A............................................................................................................................................................. 186 mm (7.32 in)

B............................................................................................................................................................. 103 mm (4.05 in)
C............................................................................................................................................................ 11.5 mm (0.45 in)
D......................................................................................................................................................... 150 mm (5.90 in)
E ........................................................................................................................................................... 65 mm (2.55 in)
F ............................................................................................................................................................. 147 mm (5.78 in)
G............................................................................................................................................................... 50 mm (1.96 in)
H............................................................................................................................................................. 152 mm (5.98 in)
J ............................................................................................................................................................... 30 mm (1.18 in)
K............................................................................................................................................................. 104 mm (4.09 in)
Lep SM4605003-0EN
Issued 09-07
Copyright
5003-11
Removal
STEP 3
STEP 1
JD00317A
JS00163A
Park the machine on hard, flat ground. Lower the tool to

the ground.
STEP 2
Install a hydraulic jack on the side frame. Using the

jack, lift the track just enough to remove the upper
roller.
STEP 4
JD00318A
JD00273A

Slacken the track by slowly loosening the non-return
check valve by about two turns, the grease will escape
from a port in the check valve thread.
Place wooden shims between the track and the

undercarriage.
STEP 5

non-return check valve or the retaining
bracket.
JD00319A
Unscrew the screws which fasten the upper roller to the

undercarriage. Support and remove the upper roller.
Lep SM4605003-0EN
Issued 09-07
Copyright
5003-12
Reconditioning
STEP 3
When the upper roller is worn or is leaking, it must be

reconditioned or a new upper roller installed. See
Section 1002 for limits of wear.
Disassembly
3
STEP 1
7
1
CS02B507
Secure the upper roller in a vice. Remove the screws

(3) holding the thrust plate (6). Remove the thrust plate
(6).
STEP 4
1
CS02B505
Clean the upper roller (1) using a suitable solvent.

Remove the drain plug (2) and drain the oil.
STEP 2
3
4
CS02B508
Pull the upper roller (1) from the shaft (7).
NOTE: Carry out Step 5 only if inspection reveals that

the shaft (7) needs to be replaced.
STEP 5
CS02B506
Remove the screws (3) and the cover (4) from the
upper roller (1). Remove and discard the O-ring (5)
from the cover (4).
Lep SM4605003-0EN
Using a press, remove the shaft (7) from the bracket

(11). Be careful not to damage the seal bore in the
bracket.
Issued 09-07
Copyright
5003-13
STEP 6
NOTE: Carry out Step 8 only if inspection reveals that

the bushings (9) and (10) need to be replaced.
STEP 8
1
9
8
1
10
CS02B509
Remove and discard the face seal (8) on the upper

roller (1) using a screwdriver or equivalent tool. Be
careful not to damage the seal bore in the upper roller.
STEP 7
7
CS02B511
Using a hammer and a brass punch, drive the bushings

(9) and (10) from the upper roller (1). Be careful not to
damage the seal bore in the upper roller.
11
11
000.6.03.00.24H
Remove and scrap the face seal (8) from the bracket
(11) using a screwdriver or other suitable tool. Be
careful not to damage the seal bore in the bracket.
Lep SM4605003-0EN
Issued 09-07
Copyright
5003-14
Inspection
STEP 1
Clean all components with solvent.
STEP 2
Inspect the bushing surfaces on the shaft (7) for
scoring, pitting and other damage. Measure the
diameter of the shaft at four opposing points. Compare
the values with the specifications, replace if necessary.
STEP 3
Check for wear and damage to the bushings. Measure
the values with the specifications, replace if necessary.
STEP 4
Inspect the thrust plate for wear and damage. Measure
the thickness of the thrust plate. Compare the values
with the specifications, replace if necessary.
STEP 5
Inspect the bore in the bracket (11) and the upper roller
(1) for damage that could result in leakage. Use new
parts as required.
Lep SM4605003-0EN
Issued 09-07
Copyright
5003-15
Assembly
STEP 3
STEP 1
1
11
CS02B509
CS02B512
If the shaft (7) has been removed from the bracket (11),
install the shaft in the bracket using a press. Be careful
not to damage the seal bore in the bracket.
Install an O-ring and a face seal (8) metal bushing in

the seal bore of the upper roller (1). Liberally apply
clean oil on the edge of the face seal.
STEP 4
NOTE: The retaining ports of the thrust plate (6) should

be perpendicular to the retaining plane of the bracket
(11).
NOTE: Respect the recess dimension of the shaft in
the bracket, see page 10.
STEP 2
11
8
9
10
7
1
000.6.03.00.24K
Install the the face seal (8) in the bracket seal bore (11).
Apply clean oil copiously to the face seal.
9
1
STEP 5
10
10
CS02B513
Install the bushings (9) and (10) in the upper roller (1).
NOTE: The grooves of the bushings should be rotated
by 90.
CS02B508
Apply clean grease on the surface of the shaft (7) and

install the shaft in the upper roller (1).
Lep SM4605003-0EN
Issued 09-07
Copyright
5003-16
STEP 6
STEP 9
1
2
3
6
1
CS02B515
Apply grease on the inside of the thrust plate (6).

Position the thrust plate on the shaft (7) and install the
screws (3). Apply brake thread fluid to the screws and
tighten to a torque of 62.8 to 72.6 Nm (46.32 lbf-ft) to
(53.55 lbf-ft).
CS02B505
Fill the upper roller (1) with synthetic oil (see the
specifications for quantity). Install the drain plug (2) in
the cover (4). Tighten the plug to a torque of 24.5 Nm
(18.07 lbf-ft).
STEP 7
3
4
5
1
CS02B506
Apply grease on the seal (5) and install in the groove of

the cover (4). Install the cover on the upper roller (1)
using screws (3). Apply brake thread fluid to the screws
and tighten to a torque of 62.8 to 72.6 Nm (46.32 lbf-ft)
to (53.55 lbf-ft).
STEP 8
Check for leaks to ensure that the upper roller has been
correctly reassembled and check for any damage which
could give rise to leaks at seals and other components.
Lep SM4605003-0EN
Issued 09-07
Copyright
5003-17
Installation
STEP 3
STEP 1
JD00317A
JD00338A
Place the shims on the undercarriage, then install and

support the upper roller.
Remove the wood blocks between the track pad and

the undercarriage.
STEP 4
Operate the hydraulic jack to lower the track onto the
upper roller. Remove the jack.
STEP 2
STEP 5
Refer to "Track tension setting" in Section 5001.
JD00319A
Apply Loctite 262 to the screw threads. Install two

tempered washers and screws to fasten the upper
roller bracket to the undercarriage. Tighten the screws
to torque (see specifications).
Lep SM4605003-0EN
Issued 09-07
Copyright
5003-18
CHECKING FOR LEAKS

shown below.
STEP 4
Connect the pressure gauge pipe to the quick coupler.
STEP 5
Make sure that the shut-off valve (1) is open.
STEP 6
Adjust the pressure regulator (2) until the pressure
gauge shows 1.9 bar (0.2 MPa/29 PSI).
STEP 7
Turn the shaft of the unit under test four revolutions.
STEP 8
2
Adjust the regulator until the pressure gauge shows

1 bar.
B407320M
STEP 1
Connect the shut-off valve (1) to the pressure regulator
(2). Connect a union for the air supply hose to the shutoff valve.
STEP 9
Close the shut-off valve. Maintain the air pressure of
Step 8 for 10 seconds. A reduction in air pressure
during this period shows a defective component or
incorrect assembling.
STEP 2
Install the adaptor and a quick coupler to the oil filler
orifice. Use a seal washer with the adapter.
STEP 3
Turn the knob anti-clockwise to close the pressure
regulator (2).
Lep SM4605003-0EN
Issued 09-07
Copyright
Section
5004
5004
SPROCKET
CNH
Lep SM160B5004-0EN

Printed in France
May 2007
Copyright
5004-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
SPROCKET.................................................................................................................................................................... 3
Removal ..................................................................................................................................................................... 3
Installation .................................................................................................................................................................. 4
SPECIFICATIONS
See Section 1002.

See Section 1002.
Lep SM160B5004-0EN
Issued 05-07
Copyright
5004-3
SPROCKET
Removal
STEP 4
STEP 1
See
Removing
and
installing
the
tracks
(Section 5001) and removing the sprocket from the
chain.
STEP 2
JD00292A
To facilitate reassembly, make alignment marks (1) on

the sprocket and the reduction gear.
STEP 5
JD00290A
Move the machine so that the track is in the position

shown.
STEP 3
JD00293A
Remove the screws (1) and the hardened washers that

attach the sprocket to the reduction gear.
STEP 6
JD00291A
Rotate the upperstructure so that the cab is over the

side of the machine where the sprocket to be removed
is located. Using the attachment, lift the side of the
machine until the teeth of the sprocket are free from the
chain.
NOTE: The photos below do not correspond to the
machine model, but the procedure is the same.
JD00294A
Drive the sprocket from the reduction gear housing

using a soft hammer. Remove the sprocket from the
machine.
Lep SM160B5004-0EN
Issued 05-07
Copyright
5004-4
Installation
STEP 3

STEP 1
JD00293A
Apply Loctite 262 to the screw threads (2). Assemble

the hardened washers and the screws.
STEP 4
JD00292A
Install the sprocket on the drive reduction gear taking

care to align the reference marks (1).
STEP 2
3
2
JS00296A
Tighten the four screws to torque in the order shown,

see "specifications". Then progressively tighten the
remaining screws to the same torque setting.
JD00295A
If necessary, use a soft hammer to seat the sprocket

properly on the flange of the reduction gear.
Lep SM160B5004-0EN
STEP 5
To install the tracks, see Removing and installing the
tracks.
Issued 05-07
Copyright
Section
5005
5005
IDLER WHEEL AND TENSION SHOCK ABSORBER
CNH
Lep SM4605005-0EN

Printed in France
September 2007
Copyright
5005-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 3
SPECIAL TOOLS ............................................................................................................................................................ 3
REMOVAL AND INSTALLATION OF THE IDLER WHEEL AND THE TENSION SHOCK ABSORBER ....................... 4
Removal ..................................................................................................................................................................... 4
Installation .................................................................................................................................................................. 6
DISASSEMBLY AND ASSEMBLY OF THE IDLER WHEEL .......................................................................................... 8
Description ................................................................................................................................................................. 8
Reconditioning ........................................................................................................................................................... 8
Disassembly ............................................................................................................................................................... 9
Inspection ................................................................................................................................................................. 10
Assembly ................................................................................................................................................................. 11
Leakage test ............................................................................................................................................................ 13
DISASSEMBLY AND ASSEMBLY OF THE TENSION SHOCK ABSORBER .............................................................. 14
Description ............................................................................................................................................................... 14
Disassembly ............................................................................................................................................................. 15
Assembly ................................................................................................................................................................. 15
TRACK TENSION CYLINDER ...................................................................................................................................... 16
Description ............................................................................................................................................................... 16
Removal ................................................................................................................................................................... 17
Disassembly ............................................................................................................................................................. 17
Inspection ................................................................................................................................................................. 18
Assembly ................................................................................................................................................................. 18
Installation ................................................................................................................................................................ 19
Lep SM4605005-0EN
Issued 09-07
Copyright
5005-3
SPECIFICATIONS
Idler wheel............................................................................................................................................. See Section 1002

Shock absorber spring yoke screw* ......................................................... 267 to 312 Nm (196,93 lbf-ft) to (230.12 lbf-ft)
Tension cylinder screw* ............................................................................ 267 to 312 Nm (196,93 lbf-ft) to (230.12 lbf-ft)
Tension cylinder non-return valve .......................................................................................................59 Nm (43.52 lbf-ft)
Mounting length of spring..................................................................................................................... 740 mm (29.13 in)
* Apply Loctite 262 to the threads
SPECIAL TOOLS
B407320M
Use CAS 1450 and CAS 1682 to check for leaks as

below
Lep SM4605005-0EN
Issued 09-07
Copyright
5005-4
REMOVAL AND INSTALLATION OF THE IDLER WHEEL

AND THE TENSION SHOCK ABSORBER
Removal
STEP 4

STEP 1
Disconnect the chain.
See "Removal and installation of the tracks", Section
5001.
STEP 2
JD00341A
Using a crowbar, move the idler wheel and the shock

absorber spring assembly out of the housing in the
undercarriage.
STEP 5
JD00339A
Start the engine. Move the machine until the track chain
is disengaged from the idler wheel. Shut down the
engine.
STEP 3
JD00342A
Move the idler wheel and the shock absorber spring

assembly out of the housing in the undercarriage, using
a crowbar, until the nylon sling can be attached to the
shock absorber spring assembly.
JD00340A
Attach the nylon sling from the lifting equipment to the

idler wheel.
Lep SM4605005-0EN
Issued 09-07
Copyright
5005-5
STEP 6
STEP 8
JD01077A
Raise and remove the idler wheel and the shock

absorber spring assembly.
STEP 7
JD00345A
Connect the lifting equipment to the idler wheel.

Remove the four screws and hardened washers which
attach the idler wheel to the yoke. Remove the idler
wheel from the yoke.
JD01078A
Place the idler wheel and the shock absorber spring on

wooden blocks. Remove the lifting equipment from the
shock absorber spring assembly.
Lep SM4605005-0EN
Issued 09-07
Copyright
5005-6
Installation
STEP 3

STEP 1
JD00342A
JD00362A
Attach a suitable lifting device to the idler wheel and

bring it into position on the yoke. Apply Loctite 262 to
the threads of the idler wheel retaining screws. Install
four hardened washers and screws to fasten the idler
wheel to the tension shock absorber yoke. Tighten the
screws to torque (see specifications).
Raise the idler wheel and the tension shock absorber

and install them in the undercarriage housing. Push the
idler wheel and the tension shock absorber into the
undercarriage. Remove the lifting device from the idler
wheel and from the back of the tension shock absorber.
STEP 4
STEP 2
JD00363A
Insert the lifting device nylon sling into the central

orifice of the tension shock absorber yoke.
JD01078A
Attach the lifting device nylon sling to the assembly.
Lep SM4605005-0EN
Issued 09-07
Copyright
5005-7
STEP 5
JD00365A
Raise the assembly and slide it into the undercarriage,

with the help of a crowbar. Remove the lifting
equipment.
STEP 6
See "Removal and installation of
(Section 5001), for installing the track.
Lep SM4605005-0EN
the
tracks"
Issued 09-07
Copyright
5005-8
DISASSEMBLY AND ASSEMBLY OF THE IDLER WHEEL

Description
B
A
CS02B516
1
2
3
4
PLUG
IDLER WHEEL
RETAINER PIN
SLIDE
5
6
7
8
SEAL
SHAFT
FACE SEAL
BUSHING
A........................................................................................................................................................... 386 mm (15.19 in)

B........................................................................................................................................................... 278 mm (10.94 in)
Reconditioning
If the idler wheel is worn to the indicated limits or if it shows traces of leaks, it must be reconditioned or changed. See
Section 1002 for limits of wear.
Lep SM4605005-0EN
Issued 09-07
Copyright
5005-9
Disassembly
STEP 3
STEP 1
2
5
1
2
6
4
CS02B519
CS02B517
Clean the idler wheel (2) with a suitable solvent. Install

the idler wheel (2) on supports, with the drain plug (1)
at the bottom. Remove the drain plug (1) from the slide
(4) and drain the oil.
Remove and scrap the O-ring (5) from the shaft (6).
Remove the shaft (6) with the slide (4) from the idler
wheel (2).
STEP 4
STEP 2
3
4
6
3
6
5
CS02B520
CS02B518
Remove the retainer pin (3) at one end. Remove the

slide (4) from the shaft (6).
Remove the retainer pin (3) from the slide (4). Remove
the slide (4) from the shaft (6), remove and scrap the Oring (5) from the shaft (6).
STEP 5
7
4
7
4
CS02B521
Remove and scrap the face seal (7) from the slide (4)
using a screwdriver or equivalent tool. Be careful not to
damage the seal bore in the slide.
Lep SM4605005-0EN
Issued 09-07
Copyright
5005-10
Inspection
STEP 6
2
STEP 1
Clean all the components with cleaning solvent. Also

clean the cavity in the idler wheel. Dry all the
components with compressed air at low pressure and
apply clean oil to all the components.
STEP 2
Inspect the bushing surfaces on the shaft for scoring,
pitting and other damage. Measure the diameter of the
shaft at four opposing points. Compare the values with
the specifications. Change them if necessary.
7
7
CS02B522
Remove and scrap the face seal (7) from the idler
wheel (2) using a screwdriver or suitable tool. Make
sure you do not damage the idler wheel seal bore.
STEP 7
8
STEP 3
Check for wear and damage to the bushings. Measure
the values with the specifications. Change them if
necessary.
STEP 4
Check for damage which could give rise to leaks at the

slide seal and idler wheel bores. Replace the
components with new components as required.
Measure the depth of the slide seal bores. Compare the
values with the specifications. Change them if
necessary.
2
CS02B523
NOTE: Carry out this step only if the inspection in Step

3 reveals that the bushings (8) have to be changed.
Using a hammer and a brass drift, drive the bushings
(8) out of the idler wheel (2). Make sure you do not
damage the idler wheel seal bore.
Lep SM4605005-0EN
Issued 09-07
Copyright
5005-11
Assembly
STEP 3
7
STEP 1
4
7
4
CS02B521
Install the remaining O-rings and remaining face seal

(7) metal bushing in the slider seal bore (4). Apply
clean oil copiously to the face seals.
2
8
STEP 4
3
4
CS02B524
A.
Clean the inside
Carefully install the bushings (8) in the idler wheel

using a press and a suitable rod.
6
5
STEP 2
2
CS02B520
Lubricate the O-rings (5) with clean grease. Install an

O-ring on the shaft (6), then install the shaft in the hub
(4). Secure the slider and the shaft with a retainer pin
(3).
7
7
CS02B522
Install an O-ring and a face seal metal bushing in the

idler wheel bore (2). Apply clean oil to the face seal lips.
Repeat this step to install the face seal on the other
side of the idler wheel.
Lep SM4605005-0EN
Issued 09-07
Copyright
5005-12
STEP 5
STEP 8
2
6
4
4
CS02B519
Apply clean grease around the shaft (6). Install the

shaft and slide (4) assembly in the idler wheel (2).
CS02B517
Fill the idler wheel (2) with clean oil (see specifications).
Install the drain plug (1) in the slide (4).
STEP 6
6
3
4
5
1
CS02B572
Apply clean grease on the O-ring (5) if this has not

already been done and install the O-ring on the shaft
(6). Install the slide (4) on the shaft and install a retainer
pin (3) to fasten the slide and the shaft. Install a drain
plug (1).
NOTE: Check the pitch of the retaining ports of the
tension shock absorber yoke, see page 8.
STEP 7
Check for leaks to ensure that the idler wheel has been
correctly reassembled and check for any damage which
could give rise to leaks at seals and other components.
Lep SM4605005-0EN
Issued 09-07
Copyright
5005-13
Leakage test
STEP 5
shown below.
Make sure that the shut-off valve (1) is open.
STEP 6
Open the pressure regulator (2) until the pressure
gauge shows 1.9 bar.
STEP 7
The shaft being checked should now be rotated four
times.
STEP 8
Close the regulator until the pressure gauge shows
1 bar.
STEP 9
B407320M
STEP 1
Connect the shut-off valve (1) to the pressure regulator
(2). Connect a union for the air supply hose to the shutoff valve.
Close the shut-off valve. Maintain the air pressure of

Step 8 for 10 seconds. A reduction in air pressure
during this period shows a defective component or
incorrect assembling.
STEP 2
Install the adaptor and a quick coupler to the oil filler
orifice. Install a seal with the adaptor.
STEP 3
Turn the knob anti-clockwise to close the pressure
regulator (2).
STEP 4
Connect the pressure gauge pipe to the quick coupler.
Lep SM4605005-0EN
Issued 09-07
Copyright
5005-14
DISASSEMBLY AND ASSEMBLY OF THE TENSION SHOCK ABSORBER

Description
CI02B500
1 SHOCK ABSORBER SPRING

2 RETAINER PIN
3 SLOTTED NUT
Lep SM4605005-0EN
4 COMPENSATOR
5 SPRING GUIDE
Issued 09-07
Copyright
5005-15
Disassembly
Assembly
STEP 1
STEP 1
Clean the shock absorber - spring assembly.
Fix the spring guide (5) in a hydraulic press.
WARNING: The shock absorber spring is

highly compressed.
STEP 2
STEP 2
Place the shock absorber spring (1) and the
compensator (4) in the hydraulic press on the spring
guide (5).
STEP 3
Operate the hydraulic press to compress the shock
absorber spring (see specifications for the value).
STEP 4
Install the slotted nut (3) and install a new retainer pin
(2) in the slotted nut and the spring guide shaft (5).
STEP 5
Remove the shock absorber spring from the hydraulic
press.
CS02E656
Place the shock absorber spring in a hydraulic press.

Use the press to compress the shock absorber spring
(1).
STEP 3
Drive out the retainer pin (2) from the slotted nut (3).
Remove the slotted nut from the spring guide (5).
STEP 4
Operate the hydraulic press so as to very slowly
release tension in the shock absorber spring (1).
STEP 5
Remove the compensator (4) and the shock absorber
spring (1) from the spring guide (5).
Lep SM4605005-0EN
Issued 09-07
Copyright
5005-16
TRACK TENSION CYLINDER

Description
1
2
3
15
14
12
13
11
7
6
8
9
10
JS01084A
1
2
3
4
5
6
7
8
SCREW
FLAT WASHER
SCREW
LOCKING WASHER
BRACKET
GREASE FITTING
CHECK VALVE
SPRING
Lep SM4605005-0EN
9
10
11
12
13
14
15
BALL
NON-RETURN CHECK VALVE BODY
CYLINDER ROD
WIPER SEAL
THRUST RING
O-RING
CYLINDER BARREL
Issued 09-07
Copyright
5005-17
Removal
STEP 3

STEP 1
JD01082A
JD01080A
Using a crowbar, push the track tension cylinder piston

rod into the cylinder barrel. The grease will flow out of
the non-return check valve pressure release orifice.
Remove the track tension cylinder from the machine.
See Section 5003 "Removal of the lower roller" and

remove the roller (A) located under the track tension
cylinder.
Disassembly
STEP 2
Using a suitable cleaning solvent and clean cloths,

remove impurities and grease from the outside of the
track tension cylinder.
STEP 1
STEP 2
Remove the two screws (3) and the locking washers
(4). Remove the bracket (5).
STEP 3
Remove the grease fitting (6) from the non-return check
valve.
STEP 4
JD01081A
NOTE: Do not allow any part of your body to pass

under the tension cylinder. You could be seriously
injured by the tension cylinder falling, when the screws
are removed which fasten it to the machine.
Unscrew the non-return check valve. As soon as the
grease starts to flow, stop unscrewing the tension
cylinder check valve. Place wooden blocks under the
tension cylinder to prevent it falling off the machine
when the two screws which attach it to the machine are
removed. Remove the two screws and the flat washers
(2).
Lep SM4605005-0EN
Remove the non-return check valve from the cylinder

barrel (15).
STEP 5
If necessary, disassemble the non-return check valve
by removing the check valve (7), spring (8) and the ball
(9) from the non-return check valve (10).
Issued 09-07
Copyright
5005-18
Assembly
STEP 6
STEP 1
11
12
14
Apply clean grease to a new O-ring (14) and new thrust

ring (13). Install the O-ring and the thrust ring in the
cylinder barrel (15).
15
STEP 2
A
13
JS01083A
Remove the cylinder rod (11) from the cylinder barrel

(15).
STEP 7
Using a screwdriver, remove the wiper seal (12) from
the cylinder barrel (15). Scrap the wiper seal.
STEP 8
Remove and scrap the thrust ring (13) and the O-ring
(14).
Inspection
STEP 1
Clean all the components with cleaning solvent.
STEP 2
JS00372A
Apply clean grease to a new wiper seal (12). Using a

hammer and a sleeve (A), drive the wiper seal into the
cylinder barrel (15) with the lip orientated towards the
outside of the cylinder barrel. Drive the wiper seal into
the cylinder barrel until it touches the cylinder barrel
shoulder. Apply clean grease to the wiper seal lip.
STEP 3
Apply clean grease around the cylinder rod (11). Install
the cylinder rod in the cylinder barrel (15).
Check for deep grooves, scratches or other damage

inside the cylinder. If necessary, use a lamp to look
inside the cylinder. Use medium abrasive emery paper
to eliminate grooves or scratches. If the grooves or
scratches are too deep or if there is other damage,
change the cylinder.
STEP 4
STEP 3
STEP 5
Check for deep grooves, scratches or other signs of

wear or damage on the cylinder rod. Use medium
abrasive emery paper to eliminate grooves or
scratches. If the cylinder rod is worn or damaged,
replace the cylinder rod.
Install the non-return check valve assembly on the

cylinder barrel (15). Tighten the non-return check valve
to torque (see specifications).
STEP 4
Check for wear or damage on the non-return check
valve assembly. Check for signs of irreparable seizure
of the spring. Change all defective components.
Lep SM4605005-0EN
If the non-return check valve has been disassembled,

install the ball (9), spring (8) and check valve (7) in the
non-return check valve body (10). Install the grease
fitting (6) in the non-return check valve body.
STEP 6
Install the bracket (5) on the cylinder barrel (15). Install
two locking washers (4) and screws (3) to fasten the
bracket to the cylinder barrel.
Issued 09-07
Copyright
5005-19
Installation
STEP 3

STEP 1
Check that the cylinder rod (11) is driven as far as
possible into the cylinder barrel (15).
STEP 2
A
JD01080A
See "Installation of the lower roller" for installing the

roller (A) under the track tension cylinder.
JD01082A
JD01081A
Move the tension cylinder into position. Apply

Loctite 262 to the threads of the two screws (1).
Support the tension cylinder while an assistant installs
two flat washers (2) and screws (1) to fasten the
tension cylinder. Tighten the screws to torque (see
specifications).
Lep SM4605005-0EN
Issued 09-07
Copyright
5005-20
NOTES
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Lep SM4605005-0EN
Issued 09-07
6001
Copyright
Section
6001
REMOVAL AND INSTALLATION OF
THE TRAVEL-MOTOR REDUCTION GEAR ASSEMBLY
CNH
Lep SM4606001-0EN

Printed in France
September 2007
Copyright
6001-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 2
SPECIAL TORQUE SETTINGS ...................................................................................................................................... 2
TRAVEL MOTOR/REDUCTION GEAR ASSEMBLY ...................................................................................................... 3
Removal and installation ............................................................................................................................................. 3
SPECIFICATIONS
Hydraulic fluid.........................................................................................................................................See Section 1002
Lubricant for reducing gear pinion
Type....................................................................................................................................................See Section 1002
Quantity.............................................................................................................................................. See Section 1002
Weight of the travel motor/reduction gear assembly ..............................................................................See Section 1002

Travel motor/reduction gear assembly to track frame retaining screw ...................................................See Section 1002
(apply Loctite 262 to the screw threads)
Drain plug, oil filling and oil level plug ........................................................147.1 14.7 Nm (108.49 lbf-ft) (10.84 lbf-ft)
(put Teflon tape around the threads)
Lep SM4606001-0EN
Issued 09-07
Copyright
6001-3
TRAVEL MOTOR/REDUCTION GEAR ASSEMBLY

Removal and installation
STEP 1
STEP 5
To prevent any fluid leaks when disconnecting hydraulic
lines, connect a vacuum pump to the hydraulic reservoir (see Section 8000).
STEP 6
1
1
JS00163A

STEP 2
STEP 3
CD00F067
Remove the four screws and washers (1) then remove

the access panel to the travel motor.
STEP 7
1
2
1
CD01K026
CD02B005
Remove the oil filler plug and the oil level plug (1) and
the drain plug (2) and drain the oil.
To facilitate reassembly, attach identification tags to the

different hoses connected to the travel motor (1).
NOTE: When installing, refer to Section 1002 for the

recommended quantity and type of oil. Tighten the
plugs to a torque of 147.7 14.7 Nm (108.49 lbf-ft)
(10.84 lbf-ft).
STEP 8
Start the vacuum pump.
STEP 4
Put Teflon tape around the plug thread and put it back
in place. Install the filling plug.
Lep SM4606001-0EN
Issued 09-07
Copyright
6001-4
STEP 9
STEP 13
1
2
CD02B005
Disconnect the hoses (1) from the travel motor (2). Plug
the hoses and the unions.
STEP 10
Stop the vacuum pump.
JD00838A
Remove the retaining screws from the travel motor/

reduction gear assembly of the undercarriage.
Remove the travel motor/reduction gear assembly from
the machine.
STEP 11
NOTE: When installing, tighten the screws to the torque

specified in Section 1002.
Refer to Section 5004 and carry out the steps for the
removal of the sprocket wheel.
STEP 14
STEP 12
6002-11
JD00836A
Connect a suitable lifting device to the travel motor/

reduction gear assembly.
NOTE: See Section 1002 for the weight of the travel
motor/reduction gear assembly.
Lep SM4606001-0EN
Place the travel motor/reduction gear assembly on a

flat surface with the drive motor turned upwards.
Remove the lifting equipment.
NOTE: When installing, follow the same procedure in
the reverse order. Replace all O-rings with new O-rings.
Fill the housing with hydraulic oil using the leak return
port. Before operating the machine, check the circuit for
leaks. Check the hydraulic oil level in the reservoir and
the oil level in the housing of the travel reduction gear,
top up if necessary.
Issued 09-07
Copyright
6003
Section
6003
OF THE SWING REDUCTION GEAR
CNH
Lep SM4606003-0EN

Printed in France
September 2007
Copyright
6003-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 2
TOOLS REQUIRED ........................................................................................................................................................ 2
SWING REDUCTION GEAR........................................................................................................................................... 3
Removal ..................................................................................................................................................................... 3
Installation .................................................................................................................................................................. 4
SPECIFICATIONS
Swing motor and swing reduction gear
Weight ............................................................................................................................................... See Section 1002
Swing reduction gear
Capacity ............................................................................................................................................ See Section 1002
Type of oil .......................................................................................................................................... See Section 1002

Swing motor retaining screws on swing reduction gear .............................. 294 to 336 Nm (216.84 lbf-ft to 247.82 lbf-ft)
Screws which attach the swing reduction gear to the upperstructure frame900 to 1050 Nm (663.80 lbf-ft to 774.43 lbf-ft)
TOOLS REQUIRED
- Hand pump CAS-10090
Lep SM4606003-0EN
Issued 09-07
Copyright
6003-3
SWING REDUCTION GEAR

Removal
STEP 5
STEP 1
Carry out Steps 1 to 10 of "Removal of the swing motor"
(see Section 8008).
STEP 2
1
JD00437A
Carefully lift the upperstructure swing motor and

reduction gear assembly, move it away from the
machine.
STEP 6
CD02E001
Attach an identification tag to the hoses (1) and (2),

disconnect them and plug the ports.
STEP 3
Mark the position of the swing reduction gear on the
upperstructure frame by making alignment marks on
the swing reduction gear and the upperstructure frame.
STEP 4
1
JS00379A
Place a container of 15 litres capacity under the swing

reduction gear drain plug. Remove the drain plug (1)
and drain the oil. Install the drain plug.
JD00449A
Remove the swing reduction gear retaining screws (1)

and the centring pin.
Lep SM4606003-0EN
Issued 09-07
Copyright
6003-4
STEP 7
Installation
Lower the swing motor/reduction gear assembly to the

ground and place it on suitable stands.
STEP 1
NOTE: The stands must be high enough to prevent the

pinion touching the ground.
STEP 8
1
JD00446A
Connect a suitable lifting device to the swing motor and

move it into position above the reduction gear. Carefully
lower the swing motor onto the reduction gear.
JD00386A
STEP 2
To facilitate reassembly, make an alignment mark (1)

on the swing motor and on the reduction gear. Remove
the swing motor retaining screws (2).
STEP 9
Carefully raise the swing motor and move it away from
the swing reduction gear. Place it in a clean area.
JD00386A
Install the swing motor retaining screws (1).

NOTE: Tighten the screws to torque.
STEP 3
Clean the upperstructure mating surface.
Lep SM4606003-0EN
Issued 09-07
Copyright
6003-5
STEP 4
STEP 6
B
A
AA
JD00437A
JD00473A
Raise the swing motor/reduction gear assembly off the

ground. Apply No. 2 EP lithium grease over the pinion
(A).
Connect the hand pump CAS-10090 to the swing motor

brake release orifice (A).
NOTE: Before installing the swing motor/reduction gear

assembly, check that the drain hose (B) is installed on
the side of the reduction gear housing.
Check that the hand pump is filled with fluid.
STEP 7
STEP 8
Operate the hand pump until the pressure gauge shows
29 bar. The swing motor brake should be released, thus
allowing the reduction gear output shaft to turn.
STEP 5
STEP 9
Lower the swing motor/reduction gear assembly onto
the upperstructure mating surface, using a dowel pin.
NOTE: Make sure that the reduction gear output gear is
correctly engaged in the upperstructure crown wheel.
STEP 10
JD00385A
Raise the swing motor/reduction gear assembly and

bring it into position above the upperstructure mating
surface, ensuring that it is in line with the alignment
marks previously made.
JD00449A
Apply Loctite 262 to the screw threads (1) and tighten

them to the torque specified in Section 1002.
Lep SM4606003-0EN
Issued 09-07
Copyright
6003-6
STEP 11
Fill the swing reduction gear with the quantity (capacity)

and type of oil specified in Section 1002. Install the oil
dipstick and check the oil level. The oil level should be
on the lower part of the dipstick. Add oil as required and
install and tighten the oil filler plug.
STEP 13
A
1
2
JD00473A
Release the hydraulic pressure in the hand pump CAS10090 and disconnect it from the swing motor brake
release orifice (A). Remove the lifting equipment from
the swing motor.
STEP 12
CT07A028
1
2
AIR BLEED PLUG

LUBRICATION ORIFICE
Remove the air bleed plug on the side of the swing

reduction gear. Pump No. 2 EP lithium grease into the
reduction gear until grease comes out of the air bleed
orifice. Install the air bleed plug.
STEP 14
2
Connect a vacuum pump to the hydraulic reservoir (see

Section 8000). Start the vacuum pump.
CT07A010
CT07A041
Check that the swing reduction gear oil drain plug (1) is
correctly tightened. Remove the oil level dipstick (2)
and the oil filler plug (3).
Lep SM4606003-0EN
Issued 09-07
Copyright
6003-7
STEP 15
STEP 18
1
2
CD02B034
CT07A009
Remove the plugs and connect the hoses (1) and (2).
Connect the earth cable to the battery.
STEP 16
STEP 19
Refer to the removal of the hydraulic swing motor and

carry out Step 8 in the reverse order.
See Section 8001 and adjust the swing motor

secondary relief valves.
STEP 17
STEP 20
Stop and disconnect the vacuum pump from the

1
2
CS02B555
Install the upper panel (1) using retaining screws (2).

NOTE: Before operating the machine, start the engine,
check the system for leaks and check the fluid level in
the hydraulic reservoir, top up if necessary.
Lep SM4606003-0EN
Issued 09-07
Copyright
6003-8
NOTES
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Lep SM4606003-0EN
Issued 09-07
Copyright
Section

DISASSEMBLY AND ASSEMBLY
CNH
Lep SM4606004-0EN

Printed in France
September 2007
6004
6004
Copyright
6004-2
TABLE OF CONTENTS
SWING REDUCTION GEAR........................................................................................................................................... 3
Description ................................................................................................................................................................. 3
Disassembly ............................................................................................................................................................... 4
Assembly ................................................................................................................................................................... 7
Lep SM4606004-0EN
Issued 09-07
Copyright
6004-3

Description
13
15
14
16
12
21
17
18
11
10
19
20
1
7
CI02B502
1
2
3
4
5
6
7
8
9
10
11
PINION
SPACER
SNAP RING
PLATE
SPHERICAL ROLLER BEARING
HOUSING
SHAFT
LIP-SEAL
SPACER
SPHERICAL ROLLER BEARING
PIN
Lep SM4606004-0EN
12
13
14
15
16
17
18
19
20
21
RING GEAR
FIRST STAGE SUN GEAR
SHIM
FIRST STAGE PLANETARY GEAR
FIRST STAGE PLANET WHEEL CARRIER
SECOND STAGE PLANETARY GEAR
RETAINER PIN
SECOND STAGE PLANET WHEEL CARRIER
SPACER
SECOND STAGE SUN GEAR
Issued 09-07
Copyright
6004-4
Disassembly
STEP 4
NOTE: The swing reduction gear is extremely heavy.

Use suitable lifting equipment to lift and move the
components.

machine model, but the procedure remains the same.
STEP 1
Place the reduction gear in a clean working area.
STEP 2
CD02B037
Remove the second stage sun gear (1).
STEP 5
1
1
CD02B035
Remove the first stage sun gear (1) and thrust ring.
STEP 3
CD02B038
Remove the second stage planet wheel carrier (1).
CD02B036
Remove the first stage planet wheel carrier (1).
Lep SM4606004-0EN
Issued 09-07
Copyright
6004-5
STEP 6
STEP 8
4
5
6
7
1
2
2
6003-090
Remove the ring gear (1) from the reduction gear

housing (2) using the notch in the housing for leverage.
NOTE: The planetary gear axles are assembled in two
ways: A = assembly by hubbing the axle; B = assembly
by blocking the axle (roll pin). According to the type of
assembly, replace the entire planet wheel carrier or
individual spare parts.
JD01465A
Remove the two screws (1), the brake plate (2), the end
plate (3) and the pinion (4). Remove the snap ring (5),
the stop (6) and the plate (7).
STEP 9
STEP 7
1
2
3
6003-096
Install the swing reduction gear in a suitable press.

Place shims under the flange on the housing to hold the
shaft upright.
JD01464A
STEP 10
Turn the swing reduction gear upside down to be able

to access the pinion (1). Straighten up the corners of
the brake plate (2) to free the screws (3).
2
1
A
6003-097
Place a jack (A) under the shaft (1) and the bearing (2)
under the press to hold and support the shaft when it
has been pressed out of the housing. Press the shaft
from the housing. Remove the shaft and the bearings
from the press.
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Issued 09-07
Copyright
6004-6
STEP 11
STEP 13
3
1
CD02B039
Remove the roller bearing (1) from the gear housing.
4
2
STEP 12
CI02B503
Place the shaft (1) under a press. Insert two shims (2),
press the shaft (1) from the bearings (3). Remove the
spacer (4).
STEP 14
JD00459A
Using a suitable tool remove the lip seal (1) from the
gear housing. Discard the lip seal.
1
CD02B040
Place the planetary gear assembly on a workbench.

Press the retainer pins (1) in the axles just enough to
remove the axles.
Lep SM4606004-0EN
Issued 09-07
Copyright
6004-7
Assembly
STEP 15
2

machine model, but the procedure remains the same.
STEP 1
Place the planet wheel carrier on a clean workbench.
STEP 2
1
CD02B041
Support the planetary gears and remove the axles from

the planet wheel carrier (2). Press the pins completely
from the axles (1). Remove the pins.
STEP 16
6003-106
Assemble the planetary gears (1), slide the thrust

washers (2) under the pinions (boom).
STEP 3
1
1
6003-105
Remove the planetary gears (1).
STEP 17
1
6003-105
Align the pinions with the bores of the planet wheel

carrier and install the axles. Take care to position the
axle retaining bore correctly (1) with respect to the bore
of the planet wheel carrier.
6003-106
Remove the thrust washers (1) from the planetary

gears.
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Issued 09-07
Copyright
6004-8
STEP 4
STEP 6
WARNING: Take precautions (gloves), risk of

burns.
A
2
3
6003-107
Install a new pin (A) in the shaft using a suitable tool.

Recess dimension in the planet wheel carrier:
B = 1 mm.
Lock it, using two strokes of a punch.
STEP 5
Position the retainer pins in the second stage planet
wheel carrier.
CI02B504
Install the spacer (1) on the shaft (2). Heat the bearing
(3) to 50C above the ambient temperature. Assemble
the hot bearing on the shaft (2), use protective gloves.
STEP 7
CS00K512
Boom: direction of rotation.
JD00465A
Degrease the reduction gear housing and apply Loctite

504. Fix the reduction gear housing in a press, install
the lip seal in the reduction gear housing. Lubricate the
lip seal with No. 2 EP lithium grease. Install the
spacers, then install the bearing on the reduction gear
side.
Lep SM4606004-0EN
Issued 09-07
Copyright
6004-9
STEP 8
STEP 10
6
5
JD00469A
Degrease the mating surfaces of the gear housing, ring

gear and the four dowel pins. Install the four dowel pins
(1) into the gear housing. Apply Loctite 504 liquid
packing to the mating surfaces.
3
4
STEP 11
CI02B505
Coat the roller bearings (1) with 800 grams of No. 2 EP

lithium grease (2). Place the shaft assembled (3) on the
shims (4) under a press. Position the housing (5)
equipped with the bearing and the lip seal on the shaft
(3). Position the shims (6) on the bearing (7). Assemble
the housing using the press (booms).
STEP 9
1
JD00470A
Install the ring gear (1) ensuring the alignment marks

are aligned. Assemble four screws (2) in opposition to
hold the ring gear (1).
2
3
4
5
6
CI02B506
Assemble the plate (1). Assemble the snap ring (2) with
a gap of about 30 mm with respect to the notch on the
housing. Install the spacer (3). Lubricate and assemble
the pinion (4). Assemble the stop plate (5). Install the
brake plate (6), assemble and tighten the screws (7).
Bend the corners of the brake plate (6) on the screw
heads (7).
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Issued 09-07
Copyright
6004-10
STEP 12
STEP 14
1
1
CD02B038
Install the second stage planet wheel carrier (1) so that

it meshes correctly with the internal teeth of the ring
gear. Turn the planetary assembly slightly to engage
the splines of the pinion shaft.
STEP 13
CD02B036
Install the first stage planetary assembly (1) so that it

meshes with the internal teeth of the ring gear. Turn the
planetary assembly slightly to mesh the teeth of the
planetary gears with the teeth of the second stage sun
gear.
STEP 15
1
1
CD02B037
Install the second stage sun gear (1) so that it meshes

with the planetary gear assembly.
Lep SM4606004-0EN
CD02B035
Install the thrust shim on the second stage sun gear.

Install the first stage sun gear (1) so that it meshes
correctly with the teeth of the planetary gears. Turn the
first stage planetary assembly by hand and check that
the output shaft rotates smoothly.
Issued 09-07
Copyright
6004-11
STEP 16
A
CS00K516.
Measure the dimension (A), position of the sun gear.

Make sure that the distance between the end surface of
the sun gear No.1 (13) and the ring gear (12) is 3.653 to
5.66 mm. If the distance falls short of reaching 3.653
mm:
Gear shaft (7) and the roller bearing (5) are dislocated.
The roller bearing (10) is not inserted completely.
Foreign substances are engaged.
If the distance is larger than 5.66 mm:
The wire (3) is not installed properly.
The ring gear (12) is not completely tightened into the
gear case (6).
Foreign substances are engaged.
Lep SM4606004-0EN
Issued 09-07
Copyright
6004-12
NOTES
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Lep SM4606004-0EN
Issued 09-07
Copyright
Section
6005
ASSEMBLY AND DISASSEMBLY
CNH
Lep SM4606005-0EN

Printed in France
September 2007
6005
TRAVEL REDUCTION GEAR
Copyright
6005-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 2
SPECIAL TORQUES ...................................................................................................................................................... 2
REDUCTION GEAR........................................................................................................................................................ 3
Description .................................................................................................................................................................. 3
Disassembly................................................................................................................................................................ 4
Inspection.................................................................................................................................................................... 9
Assembly .................................................................................................................................................................. 10
SPECIFICATIONS
See Section 1002.
SPECIAL TORQUES
Screw *(4).............................................................................................................. 461 44.1 Nm (340.01 32.52 lbf-ft)
Screw *(6) ............................................................................................................. 53.9 5.9 Nm (39.75 4.35 lbf-ft)
Screw *(28)..................................................................................................................68.6 6.9 Nm (50.60 5.09 lbf-ft)
Plug (29).................................................................................................................147 14.7 Nm (108.42 10.84 lbf-ft)
* .............................................................................................................................................(With applying Loctite #242)
Lep SM4606005-0EN
Issued 09-07
Copyright
6005-3
REDUCTION GEAR
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
HOUSING
BEARING
RING GEAR
SCREW
COVER
SCREW
FLOATING SEAL
SHIM
LOCK WASHER
SUPPORT RING
CARRIER 2
PLANETARY GEAR 2
RETAINING RING
BEARING
CARRIER PIN 2
Lep SM4606005-0EN
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
SPRING PIN
SPACER
SUN GEAR 2
CARRIER 1
PLANETARY GEAR 1
THRUST WASHER 1
NEEDLE BEARING
CARRIER PIN 1
SPRING PIN
SUN GEAR 1
THRUST PLATE
COVER
SCREW
PLUG
O-RING
Issued 09-07
Copyright
6005-4
Disassembly
General precautions
1. Its common that a reduction unit which has been
dismounted from the machine is covered with dirt or
dust. Wash and dry the exterior of the unit.
2. Loosen the drain and filler plug (29) to drain oil in
the reduction unit.
WARNING: Safety is priority while disassembling. Be careful and avoid hands from being
caught between parts or lifted parts from falling
on your feet.
STEP 2
WARNING: If the oil is still hot, internal pressure

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

outer side of each mating face in order to put the
faces back into their original locations when assembling.
NOTE: Numbers in parentheses following the part
names shown in the description below correspond to
symbols in the structural drawings.
STEP 1
Remove the srews (28) that secure cover (27).
STEP 3
As the cover (27) is adhered to ring gear (3), remove

cover (27) by lightly hammering slantwise upward by
wooden bar aiming at projection of cover (23).
Remove the screws (28) at 3 places from cover (27)

almost equally apart each other, then install M12 eye
bolts.
Lift up the unit using them and place it on work stand
with cover (27) upward.
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Issued 09-07
Copyright
6005-5
STEP 4
Remove thrust plate (26).

Screw three M10 eye bolts in carrier 1 (19) and lift up
and remove carrier 1 as sub-ass'y (19), (20), (21), (22),
(23), (24).
Remove sun gear 1 (25).
STEP 7
Remove the lock washer (9) by placing a screwdriver or

equivalent to the washers split part and tapping the
driver with a hammer.
STEP 8
STEP 5
Remove sun gear 2 (18).

Screw three M10 eye bolts in carrier 2 (11) and lift up
and remove carrier 2 as sub-assembly (11), (12), (13),
(14), (15), (16) and (17).
STEP 6
Screw three M12 eye bolts in ring gear (3) almost

equally apart each other, then lift it up horizontally and
remove housing assembly including ring gear (3), housing (1), angular bearing (2), seal cover (5), floating seal
(7) and screws (4) together.
Remove the support ring (10).
Lep SM4606005-0EN
Issued 09-07
Copyright
6005-6
STEP 12
OVER 300
STEP 9
Screw three M24 eye bolts in housing (1) almost

equally apart each other. Lift up the housing assembly
and place it on work stand with housing (1) upward.
Put a mating mark outside of housing (1) and ring gear
(3).
NOTE: Take care not to damage the sliding surface of
floating seal (5) or its O-ring.
Bearings (2) have been tightly press fitted in housing
(1). Don't remove the bearings (2) unless otherwise
their exchange is needed.
In case bearings (2) removed, don't re-use them.
New bearings (2) should be used and shim (8) adjusting be required.
STEP 10
Knock spring pins 6 x 36 (24) fully into carrier pins 1

(23).
Tap carrier pins 1 (23) out from carrier 1 (19).
Remove thrust washers 1 (21), planetary gears 1 (20)
and needle bearings (22) from carrier 1 (19).
NOTE: When carrier pins 1 (23) are to be re-used,
mark each pin with its mated hole of carrier 1 (19) to
assure the same combination as before.
Remove floating seal (7) from seal cover (5).

Remove the srews (6), and remove seal cover (5) from
housing (1).
Remove the screws (4), leaving two of them diagonally.
Loosen the other screws (4) and tap lightly the head of
them then ring gear (3) can be easily removed from
housing (1).
STEP 11
Remove a piece of floating seal (7) of motor side.
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Issued 09-07
Copyright
6005-7
STEP 13
STEP 14
Knock out spring pins 6 x 36 (24) from carrier pins 1

(23) for re-assembling.
NOTE: When carrier pin 1 (23) or planetary gear 1 (20)
is needed to be exchanged, three pins or three gears
should be all exchanged.
Knock spring pins 10 x 63 (16) fully into carrier pins 2

(15).
Tap carrier pins 2 (15) out from carrier 2 (11).
NOTE: When carrier pins 2 (15) are to be re-used,
mark each pin with its mated hole of carrier 2 (11) to
assure the same combination as before.
Lep SM4606005-0EN
Issued 09-07
Copyright
6005-8
STEP 15
Inspection
1. Thrust washers
Inspect if there is any seizure, abnormal wear, uneven wear, or other.
Check that the wear is within allowable values.
2. Gears
Check for pitching and seizure on the face of tooth.
Check the colour on the root of tooth to find out
cracks.
3. Bearing
Make sure that there are no noises or engagement
by manually rotating the bearing.
4. Floating seal
Check if there is any damage on the sliding faces of
O-rings.
Remove planetary gears 2 (12), bearing (14) and

retaining ring C-type (13) from carrier 2 (11).
Remove spacer (17) from carrier 2 (11).
Knock out spring pins 10 x 63 (16) from carrier pins 2
(15) for re-assembling.
NOTE: Take great care not to pinch your hand between
gears and carrier 2 (11) while disassembling.
NOTE: When carrier pin 2 (15) or planetary gear 2 (12)
is needed to be exchanged, three pins or three gears
should be all exchanged.
Lep SM4606005-0EN
Issued 09-07
Copyright
6005-9
Mark
Item
Reference value (mm)
Allowable value (mm)
Remedy
Wear on the planetary

shaft
Smooth, no abnormal
wear and seizure
Smooth, no abnormal
wear and seizure
Replace 3 pieces
as a set
Conditions on face of
tooth and root of tooth
Smooth, no abnormal
wear and seizure
No pitching of dia. 1.6

or more, no cracks on
the root of tooth
Replace
(Replace 3 pieces as a
set for planetary gears)
Thrust spaces in the inner

race of angular bearings
(2)
- 0.08 to 0.02
- 0.08 to 0.02
Adjust shim
thickness
(see page 12)
Thickness of thrust
washer 1 (21)
From 3.9 mm
To 4.1 mm
0.1 of wear
Replace
Thickness of spacer (17)
From 4.2 mm
To 4.6 mm
0.15 of wear
Replace
Thickness of thrust plate

(26)
From 4.34 mm
To 4.66 mm
0.15 of wear
Replace
Lubrication oil
2,000 working hours (engine hour meter)
Lep SM4606005-0EN
Replace
Issued 09-07
Copyright
6005-10
Assembly
STEP 3
General precautions
1. Wash each part with treated oil, then dry it completely with air. For the surfaces to which Loctite is
applied, degrease with thinner or equivalent.
2. Check for any abnormality on each part.
3. Tighten hexagonal socket head cap screws upon
application of Loctite.
4. Apply a thin coat of gear oil to assembly parts prior
to the assembly.
WARNING: Be careful and avoid hands from

being caught between parts or lifted parts from
falling on your feet.
SLOT DIRECTION TURNS
CALK TWO PLACES
TO COVER SIDE
180 DEGREE POSITION
STEP 1
COVER SPRING PIN OF 5 mm BY

CALKING
SINK SPRING PIN OF 1 to 2

mm FROM SURFACE
PINION
Calk carrier 2 (11) on diagonally position to prevent

spring pin 10 x 63 (16) from coming out.
Install spacer (17), planetary gears 2 (12), bearings
(14) and retaining ring C-type (13) into carrier 2 (11).
NOTE: Refer to "Detail of calking
STEP 4
STEP 2
Install carrier pins 2 (15) into carrier 2 (11) where the

holes for spring pins 10 x 63 (16) are to be in line with
those of carrier 2 (11).
Install spring pins 10 x 63 (16) into carrier 2 (11) and at
the same time into carrier pins 2 (15).
(Sink spring pins of 1 - 2 mm from surface).
Lep SM4606005-0EN
Install planetary gears 1 (20), needle bearings (22) and

thrust washers 1 (21) into carrier 1 (19).
Issued 09-07
Copyright
6005-11
STEP 5
CORRECT
Install carrier pins 1 (23) into carrier 1 (19) where the

holes for spring pins are to be in line with those of carrier 1 (19).
Install spring pins 6 x 36 (24) into carrier 1 (19) and at
the same time into carrier pins 1 (23).
(Sink spring pins of 1 - 2 mm from surface)
STEP 6
INCORRECT
INCORRECT
NOTE: Clean the groove for floating seals (7) to eliminate oil, dust, paint or other foreign material.
NOTE: Apply gear oil slightly on sliding surfaces of
floating seals (7) before assembling but strictly dry on
O-rings and on its grooves
NOTE: Confirm that O-ring of floating seals (7) are not
twisted and that floating seals are correctly installed.
i.e. parallel as shown each other between seal cover
(5) and motor casing after assembled. It is recommended to use jig to install floating seal
STEP 8
LOCTITE No. 515
Calk carrier 1 (19) on diagonally position to prevent

spring pin 6 x 36 (24) from coming out.
NOTE: Refer to "Detail of calking" (See step 3).
STEP 7
Apply Loctite No. 515 to the mating surfaces of housing

(1) and ring gear (3) without a gap.
Install seal cover (5) on housing (1).
Then, after applying Loctite #242 on the threads of 16
pieces of screws M10 x 25 (6) without removing rust
preventive agent, tighten them with torque wrench.
Tightening torque of screw M10 x 25 (6) is 53.9 5.9Nm (39.75 lbf-ft 4.35 lbf-ft).
NOTE: Refer to below "How to apply Loctite #242".
Install main bearing (2) to inner surface of housing (1).

Install a piece of floating seal (7) on motor casing and
also install another piece of floating seal (7) on seal
cover (5).
Soak 20mm length from the tip
of bolt in loctite #242
Lep SM4606005-0EN
Issued 09-07
Copyright
6005-12
STEP 9
STEP 11
LOCTITE No. 515
NOTE: This process is necessary when any motor

(casing), housing (1), bearing (2) or lock washer (9) is
changed. As this is not the case, use the old shims (8)
as they are.
Apply Loctite #515 on mating surfaces of housing (1)

and ring gear (3) without a gap.
STEP 10
1. Fit in two bearings (2) on housing (1) pressing their

outer laces
2. Press inner laces of two bearings (2) lightly and
evenly, measure the assembling width "A" of inner
laces.
NOTE: When measuring the assembling width "A",
rotate bearings (2) at least 5 times and become the
width "A" stably.
Install three M24 eye bolts equally apart on housing (1).
Using the eye bolts, hang the housing (1) by wire rope
and place it on ring gear (3), coinciding mating marks.
After applying Loctite #242 on the threads of 26 pieces
of screws M20 x 120 (4) without removing rust preventive agent tighten them with torque wrench.
Tightening torque of screw M20 x 120 (4) is 461
44.1N-m (340.01 lbf-ft32.5 lbf-ft).
3. Measure the motor side assembling width "B" for

bearings (2).
NOTE: Refer to step 8, "How to apply Loctite #242".
6. Suppose the thickness of a shim (8) to be used is S,

the space X is expressed as follows:
X = (B + C) - (A + D + S)
4. Measure the groove width "C" of motor casing.

5. Measure the thickness "D" of lock washers (9).
NOTE: Measure them at 4 places evenly apart on the
circumferences then calculate and use those mean values. Measure them to the accuracy of 0.01 mm.
7. Select a shim (6) so as the clearance X to come to 0.08 mm (interference) - +0.02 mm (clearance) on
this unit.
Lep SM4606005-0EN
Issued 09-07
Copyright
6005-13
STEP 12
STEP 15
Place motor on work stand with the shaft upward, and

put the selected shim (8) (Refer to step 11, page12) on
the bearing mating surface of motor casing.
STEP 13
Press
Install support ring (10) over outside of lock washers

(9).
STEP 16
Install three M12 eye bolts on ring gear (3) almost

equally apart and lift it up. Descend it concentric with
motor and put bearings (2) on housing (1) into motor
casing. Use press machine and press inner lace of
bearing (2) into full depth.
STEP 14
Install three M10 eye bolts equally apart on carrier 2
(11).
Using the eye bolts, hang the carrier 2 assembly by
wire rope and place three planetary gears 2 (12), put
carrier 2 assembly into ring gear (3) and mesh the
splines to those of motor.
NOTE: Positioning carrier 2 assembly is important to
obtain better lubrication (see the figure below).
Carrier 2
Planetary gear 2
While pressing inner lace of bearing (2), install lock

washers (9) into groove.
Motor port
Lep SM4606005-0EN
Issued 09-07
Copyright
6005-14
STEP 17
STEP 20
Insert and mesh sun gear 2 (18) on center.
LOCTITE No. 515
STEP 18
Apply Loctite No. 515 on mating surfaces of cover (27)

and ring gear (3), and install the cover (27) on ring gear
(3).
Install three M10 eye bolts equally apart on carrier 1

(19).
Using the eye bolts, hang the carrier 1 assembly by
wire rope and place it in ring gear (3), rotate planetary
gears 1 (20) by hand and adjust carrier 1 (19) to mesh
with sun gear 2 (18).
Making sure that coupling is on the shaft end, install
sun gear 1 (25) on center.
NOTE: Gear oil can be filled before installing cover (27)

if you can measure prescribed volume of oil.
NOTE: Refer to Step 8, page 11 "How to apply Loctite
#242".
STEP 21
STEP 19
Cover
Sharp edge
Thrust plate
Apply Loctite No. 242 to the screws (28) and fasten

them with tightening torque of 68.6 6.9 Nm (50.60 lbfft 5.08 lbf-ft).
STEP 22
Fill gear oil (GEAR 135H EP)15 litters from two G3/4
ports.
Place thrust plate (26) on carrier 1 (19).
STEP 23
NOTE: Face sharp edged side to cover (27) (see the

figure above).
Tighten taper screw plugs (29) to a torque of 147.1

14.7N-m (108.4910.84 lbf-ft).
Lep SM4606005-0EN
Issued 09-07
Copyright
Section
8000
DEPRESSURISING AND DECONTAMINATING THE
HYDRAULIC SYSTEM, USE OF THE VACUUM PUMP
CNH
Lep SM4608000-0EN

Printed in France
September 2007
8000
AND BLEEDING THE COMPONENTS
Copyright
8000-2
TABLE OF CONTENTS
SPECIAL TOOLS ............................................................................................................................................................ 3
RELEASING PRESSURE IN THE HYDRAULIC SYSTEM............................................................................................. 4
BLEEDING AIR FROM THE MAIN HYDRAULIC SYSTEM COMPONENTS ................................................................. 5
Hydraulic pump .......................................................................................................................................................... 5
Hydraulic swing motor ................................................................................................................................................ 5
Attachment cylinders .................................................................................................................................................. 5
VACUUM PUMP ............................................................................................................................................................. 6
Installation .................................................................................................................................................................. 6
Removal ..................................................................................................................................................................... 6
CLEANING THE HYDRAULIC SYSTEM ........................................................................................................................ 7
General ...................................................................................................................................................................... 7
Types of contamination .............................................................................................................................................. 7
Decontamination of the hydraulic system .................................................................................................................. 8
Lep SM4608000-0EN
Issued 09-07
Copyright
8000-3
SPECIAL TOOLS
806128
CAS 10508 - Kit for unions

806127
CAS 10162A - Portable filter
CS99B532
CAS 30038 - Set of hydraulic flow and pressure test

unions
M1325
CAS 10193 - Kit for vacuum pump
Lep SM4608000-0EN
Issued 09-07
Copyright
8000-4
RELEASING PRESSURE IN THE HYDRAULIC SYSTEM

IMPORTANT: Before carrying out any operation on the
hydraulic system, pressure in all the hydraulic circuits
must first be at zero.
STEP 5
STEP 1
Place the machine on flat, level ground, with the
attachment lowered to the ground, then shut down the
engine.
STEP 2
Place the starter switch key (1) in the "OFF" position.
STEP 6
Place the starter switch key (1) in the "ON" position.
STEP 3
Press the button (1) located above the breather to

release any remaining pressure.
Lower the function cancellation control arm (exit safety

bar).
STEP 4
Operate the control levers ten times to right and left and
backwards and forwards.
Lep SM4608000-0EN
Issued 09-07
Copyright
8000-5
BLEEDING AIR FROM THE MAIN HYDRAULIC SYSTEM COMPONENTS

IMPORTANT: After having bled the air from the
components, shut down the engine for five minutes and
then check that no air bubbles appear in the hydraulic
fluid reservoir.
Hydraulic swing motor
Hydraulic pump
CT07A010
CT07A037
Using a solvent, clean the upper surface of the pump

and the air bleed plug. Remove the air bleed plugs.
Fill the pump with hydraulic fluid via that orifice. Install
and tighten the air bleed plugs.
Start the engine, engine speed in idle mode. Loosen
the pump air bleed plugs. Retighten the plugs as soon
as the fluid flows without air bubbles from the ports.
Clean carefully around the plugs
Lep SM4608000-0EN
Start the engine and run it at idle. Loosen the air bleed
plug and make sure that hydraulic fluid flows out of that
orifice. If necessary, shut down the engine and top up
via that orifice. Install the plug, without tightening it,
then start the engine and run it at idle. Let it run until
hydraulic fluid flows out of the orifice. Completely
retighten the air bleed plug. Perform at least two
complete swings of the upperstructure, both to right
and to left.
Attachment cylinders
Start the engine and run it at idle. Extend and retract all
the cylinder rods four or five times without bringing
them against the stops, then do the same again three
or four times, but this time bringing the cylinder rods
against the stops.
Issued 09-07
Copyright
8000-6
VACUUM PUMP
Installation
Removal
STEP 1
STEP 1
Release pressure in the hydraulic system, see page 4.
Disconnect the vacuum pump harness from the

batteries.
STEP 2
STEP 2
Disconnect the vacuum pump from the elbow union of
the adaptor plate (B).
STEP 3
Remove the adaptor plate (B) from the hydraulic
reservoir and scrap the O-ring.
STEP 4
Install a new O-ring on the hydraulic reservoir and
install the plate (A).
Remove the plate (A) on top of the hydraulic reservoir.
NOTE: Do not remove the O-ring from the reservoir.
STEP 3
B
JD00019A
Install the adaptor plate (B) from the kit CAS 30028 on
the hydraulic reservoir.
STEP 4
JD00020A
Connect the vacuum pump CAS 10193 to the elbow

union of the adaptor plate. Connect the vacuum pump
harness to the batteries.
Lep SM4608000-0EN
Issued 09-07
Copyright
8000-7
CLEANING THE HYDRAULIC SYSTEM

General
Types of contamination
Contamination of the hydraulic system is a major cause

of incorrect operation of hydraulic components.
Contamination manifests itself by the presence of
foreign bodies in the hydraulic fluid. Contamination of
the hydraulic system can occur in any of the following
situations:
Contamination exists
microscopic or visible.
1. When draining fluid 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 still operate even when
slightly contaminated. Components of the hydraulic
system are designed to withstand a slight degree of
contamination. Any increase in the degree of
contamination causes serious problems in the hydraulic
system.
Here is a non-exhaustive list of these problems:
1. Cylinder rod seals leak.
2. Control valve spools do not return to the neutral
position.
basically
in
two
forms:
1. We speak of microscopic contamination when very

small particles of foreign bodies are in suspension
in the hydraulic fluid. These particles are too small
to be seen or felt. Microscopic contamination can be
identified by the problems connected with
microscopic contamination or by tests in the
laboratory. Here are a few examples of the
problems caused by microscopic contamination:
A. Cylinder rod seals leak.
B. Control valve spools do not return to the neutral
position.
C. The hydraulic system working temperature is high.
D. Components wear quickly.
2. We speak of visible contamination when the presence

of foreign bodies can be detected visually or by touch
or smell. Visible contamination can cause a sudden
failure of a component. Here are a few examples of
problems caused by visible contamination:
A. The fluid contains metal or other debris.
B. The fluid contains air.
C. The fluid is dark and thick.
3. Control valve spools are hard to move.
D. The fluid smells burnt.
4. Hydraulic fluid is too hot.
E. The fluid contains water.
5. Hydraulic components wear quickly.

6. Safety valves or non-return check valves do not close,
due to contamination.
7. Repaired components soon fail again.
8. Cycles are slow; the machine does not have enough
power.
If one of the above situations occurs, it shows
excessive contamination of the hydraulic system. To
eliminate this contamination effectively, use the
portable filter CAS 10162A.
Lep SM4608000-0EN
Issued 09-07
Copyright
8000-8
Decontamination of the hydraulic

system
STEP 7
2
STEP 1
Prepare the portable filter CAS 10162A as follows:

1. Eliminate all hydraulic fluid from the inlet and outlet
hoses of the portable filter.
2. Remove the cartridge of the portable filter.
3. Eliminate all the hydraulic fluid from the portable
filter.
4. Clean the interior of the cartridge housing.
5. Install a new filter cartridge.
CD00E178
STEP 2
Remove the bleed lever valve (1) under the hydraulic

reservoir. Do not remove the adaptor (2).
Release pressure in the hydraulic system, see page 4.
STEP 8
STEP 3
Install the shut-off valve from the union kit CAS 10508 on
the adaptor (2).
Drain the hydraulic fluid from the reservoir, see the

operators manual.
NOTE: Make sure that the shut-off valve is closed.
NOTE: Do not assemble the access door under the

hydraulic reservoir.
STEP 9
STEP 4
Fill the hydraulic reservoir with clean hydraulic fluid.

See the Operators Manual.
Change the breather cartridge, the return filter and

clean the inlet filter, see the operators manual.
STEP 10
NOTE: Do not install the plate complete with the

breather.
STEP 5
Install the inlet hose from the portable filter on the shutoff valve under the hydraulic reservoir.
STEP 11
Change the pilot circuit filter, see the operators manual.
Install the long pipe from the union kit CAS 10508 on
the portable filter return hose.
STEP 6
STEP 12
Change the Ultra Clean filter, see the operators

manual.
Insert the long pipe in the hydraulic reservoir. Move the

inlet filter long pipe as far away as possible.
STEP 13
Open the shut-off valve under the hydraulic reservoir.
Lep SM4608000-0EN
Issued 09-07
Copyright
8000-9
STEP 14
STEP 25
Install the portable filter on the upperstructure in such a

manner that the machine can be operated. Attach the
portable filter firmly to the machine.
Stop the portable filter and the engine.
STEP 15
Close the shut-off valve under the hydraulic reservoir.
Connect the electric cable from the portable filter to the

batteries. Make sure that the electric cable is away from
any moving components.
STEP 26
STEP 27
Remove the inlet pipe from the shut-off valve under the
hydraulic reservoir.
STEP 16
STEP 28
Start the portable filter running.
Remove the long pipe from the hydraulic reservoir.
STEP 17
STEP 29
Start the engine, run it at half maximum speed for ten

minutes. During those ten minutes, stir the hydraulic
fluid in the hydraulic reservoir with the long pipe.
Disconnect the portable filter electric cable from the

batteries and remove the portable filter from the
machine.
STEP 18
STEP 30
Set engine speed to maximum and bring the hydraulic

fluid up to its operating temperature by the following
procedure:
Install a vacuum pump on the hydraulic reservoir. See

page 6.
1. Operate the bucket and dipper controls in one

direction (against the cylinder stops) for
30 seconds.
STEP 31
2. Operate the bucket and dipper controls in the other

direction (against the cylinder stops) for 30 seconds.
3. Repeat steps 1 and 2 until the hydraulic fluid
temperature reaches 45 to 55C (third bar on the
hydraulic fluid temperature gauge on the illuminated
instrument panel control screen).
STEP 19
With the engine at full speed; operate each cylinder
(retract, extend) two times, one after another, for
45 minutes.
STEP 20
With the engine at full speed; operate the swing control
several times 180 to the left and then to the right.
STEP 21
With the engine at full speed; position the attachment at
right angles to the undercarriage. Use the attachment
to raise the track off the ground. Operate the travel
pedal, in one direction for two minutes and then in the
other direction for two minutes. Repeat this cycle for ten
minutes.
STEP 22
Repeat Step 21 for the other track.
STEP 23
Reduce the engine speed to idle.
STEP 24
Stir the hydraulic fluid in the hydraulic reservoir for
10 minutes with the long pipe.
Lep SM4608000-0EN
Issued 09-07
Copyright
8000-10
STEP 32
2
1
CD00E178
Remove the shut-off valve from the adaptor (2) and

install the bleed lever valve (1).
NOTE: Make sure that the bleed lever valve is closed.
STEP 33
Stop the vacuum pump and remove it from the
hydraulic reservoir. See page 6.
STEP 34
Install the access panel under the hydraulic reservoir.
STEP 35
Change the return filter and clean the inlet filter. See
the Operators Manual.
STEP 36
Change the pilot system filter. See the Operators
Manual.
STEP 37
Change the Ultra-Clean filter, see the operators
manual.
STEP 38
Check the level of the hydraulic fluid. Top up as
necessary. See the Operators Manual.
Lep SM4608000-0EN
Issued 09-07
8001
Copyright
Section
8001
SPECIFICATIONS, TROUBLESHOOTING,
INSPECTIONS AND HYDRAULIC PRESSURE SETTING
CNH
Lep SC4608001-0EN

Printed in France
March 2007
Copyright
8001-2
TABLE OF CONTENTS
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see
this symbol, carefully read the message which follows. Your safety depends on it.
SPECIFICATIONS .................................................................................................................................................... 3
SPECIAL TOOLS ...................................................................................................................................................... 3
Tester .................................................................................................................................................................... 3
IDENTIFICATION OF HYDRAULIC COMPONENTS ............................................................................................... 5
Pump..................................................................................................................................................................... 5
Control valve ......................................................................................................................................................... 6
6 solenoid valve row ............................................................................................................................................. 7
PREPARATION BEFORE INSPECTION.................................................................................................................. 8
Releasing pressure in the hydraulic system.......................................................................................................... 8
Main pressure measuring port .............................................................................................................................. 9
Installing the pilot pressure test point.................................................................................................................... 9
Flow curve........................................................................................................................................................... 10
Display on the "CHK1" monitor display ............................................................................................................... 11
Warming up the engine ....................................................................................................................................... 11
Warming up the hydraulic fluid............................................................................................................................ 11
CHECKING AND SETTING PROCEDURE ............................................................................................................ 12
Main pilot system relief (H).................................................................................................................................. 13
Checking the pilot accumulator ........................................................................................................................... 13
Main relief (A)...................................................................................................................................................... 13
Attachment control valve secondary reliefs......................................................................................................... 15
Swing port secondary relief................................................................................................................................. 16
Checking the pressure delivered by the proportional valve ................................................................................ 17
PROCEDURE FOR CHANGING OPERATION TYPE ............................................................................................ 18
ISO type .............................................................................................................................................................. 18
Old Sumitomo type ............................................................................................................................................. 18
Old Mitsubishi type.............................................................................................................................................. 19
Old Kobelco type................................................................................................................................................. 19
Lep SC4608001-0EN
Issued 03-07
Copyright
8001-3
SPECIFICATIONS
See section 1002.
SPECIAL TOOLS
Tester
1
3
CD01B005
CP96E001
1. TEST KIT E5444449 FOR MULTI-HANDY 2051
2. FEMALE COUPLING JOINT E47894 (1)

PRESSURE TEST POINT 14X1.5 A3237549 (2)
MALE COUPLING JOINT WITH UNION (3) AND
PLUGS (4) CONTAINED IN THE SUITCASE CAS
30038
The Multi-Handy tester can be used every day in the

workshop for normal operations.
The Multi-Handy can be used for:
Checking pressure (two pressure scales), maximum
pressure, differential pressure (P delta), temperature,
engine rpm and flow.
1 Multi-Handy 2051 tester .......................... D5444448
2 pressure detectors (0-600 bar)................ V5344460
2 straight unions for detector..................... W5344461
1 elbow union for detector .......................... X5344462
1 engine rpm detector ................................ Z5344463
3 cables (5 m long)..................................... E3144472
1 electric socket 220 V - 50 Hz .................. D5344467
1 cigarette lighter cable .............................. E5344468
1 instruction manual .................................... ------------1 carrying case........................................... N5344476
Lep SC4608001-0EN
CD98M009
3. 600 LITER FLOWMETER, ORDER THE

FOLLOWING:
ONE FLOWMETER RE3 Z5344486
TWO PLATES (M45X2) D4323359
TWO FLANGES ( 24) B8230183
FOUR HALF FLANGES D4024267
EIGHT SCREWS (12X75) Z1232983
Issued 03-07
Copyright
8001-4
CS99B532
4. SET OF UNIONS FOR PRESSURE TEST AND

HYDRAULIC FLOW CAS 30038.
CD99C002
5. SET OF HIGH PRESSURE HYDRAULIC HOSES

CAS XXXXX (INCLUDING TWO HIGH
PRESSURE HOSES).
Lep SC4608001-0EN
Issued 03-07
Copyright
8001-5
IDENTIFICATION OF HYDRAULIC COMPONENTS

Pump
Pi1
Dr
Psv
Pi2
a4
A3
Psv
a3
B1
Dr6
a1
a2
B3
A1
A2
CI02C509
Port
Description
Location
A1 - A2
Main pump output
SAE6000 psi 1"
B1
Main pump intake
SAE2000 psi 3"
Dr
Leak return
G 3/4 - 23
Proportional valve supply port
G 1/4 - 15
Negative pressure port
G 1/4 - 15
Psv
Pi1 - Pi2
a1 - a2 - a3 - a4 Pressure test port
G 1/4 - 15
A3
Pilot pump output
G 1/2 - 19
B3
Pilot pump intake
G 3/4 - 20.5
Dr6
Pilot pump leak return
G 3/8 - 15
Lep SC4608001-0EN
Issued 03-07
Copyright
8001-6
Control valve
Ps2
Pa10
Pc5
Ps1
CI02C508
T3
T1
T2
Pc4
Pc1 DR1'
A5
A8
T5
B5
A4
Pc2 DR2'
B8
B4
A2
A7
B7
PA
A6
B6
PP
P3
PT
PH
B2
B1
P1
Pr1
Pr2
P2
A1
CI01N508
Port
Description
CI01N507
Port
Description
B8
Bucket opening
Ps1 - Ps2
Negative pressure
A8
Bucket closing
PT
Travel pilot pressure switch
B7
Boom lowering
PA
Attachment pilot pressure switch
A7
Boom raising
Pr1 - Pr2
Pressure text point P1 and P2
B6
RH front travel
PH
Main relief power boost control
A6
RH rear travel
PP
Pilot pressure
B5
Dipper out
DR1' - DR2'
A5
Dipper in
T3
Swing motor leak return
B2
LH swing
T5
Leak return to Ultra-clean filter
A2
RH swing
T6
To pilot cushion (pre-heating)
B4
Option circuit
Pc1
Dipper load holding
A4
Option circuit
Pc2
Boom load holding
B1
LH forward travel
Pc4
Priority to the swing (dipper)
A1
Load holding valve leak return
LH reverse travel
Pc5
Priority to boom raising
P1 - P2
Pump pressure
Pa10
By-pass 2nd flow on option
T1 - T2
Return to reservoir
Lep SC4608001-0EN
Issued 03-07
Copyright
8001-7
6 solenoid valve row

Y1
Y5
Y4
Y6
Y3
Y2
CD00E143
Port
Description
Pilot manifold supply
Return to reservoir
Y1
Swing pilot shut-off
Y2
Pilot pressure cancellation control
Y3
Swing brake control
Y4
Select travel 2nd speed
Y5
Power boost
Y6
Pilot cushion control cancellation
Lep SC4608001-0EN
Issued 03-07
Copyright
8001-8
PREPARATION BEFORE INSPECTION
WARNING: Hydraulic fluid output under pressure can penetrate the skin. Hydraulic fluid can also cause or
infect a slight skin cut. In the event of being injured by hydraulic fluid under pressure, consult a doctor immediately. Any delay in obtaining treatment for an injury can cause a serious infection or reaction. Before pressurising the circuits, make sure that all the connections are correctly tightened and that the hoses and pipes are in
good condition. Release pressure in the circuits completely before disconnecting pipes or carrying out any
operation on the hydraulic system. Always use a small piece of cardboard or wood to detect leaks of fluid under
pressure. Never use your hands.
WARNING: Any incorrect use or maintenance

of a construction machine can cause accidents. Only persons who have read, understood and who observe the instructions in the
operator's manual are accredited to use or
maintain this machine.
WARNING: The accumulator of this machine

is charged with nitrogen under pressure. In the
event of incorrect operation of the circuit,
change the accumulator. Never attempt to
repair it. Non-observance of these instructions
and the procedure shown below can cause
serious or fatal injury.
Releasing pressure in the hydraulic system

NOTE: Operation to be carried out before every service
operation on the hydraulic system.
1. Position the machine on hard, flat ground.
7. Lower the pilot control cancellation lever.

8. Operate each control more than 10 times in both
directions to release pressure in the circuits.
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. Check with the diagnostic display in "S" mode that
the following values are shown.
CH
K
CS00E544
MODE II S
ENG
1800
rpm
9. Press the button located on the hydraulic reservoir

breather to release pressure in the reservoir.
1
P1
034.3
MPa
0405
mA
P2
034.3
MPa
WT
0080
0.25
MPa
OT
0055
Engine rpm
180010 rpm
Current
405 mA
5. Lower the engine speed to idle for 30 seconds, then

6. Turn the starter key switch to "ON", without starting
the engine.
Lep SC4608001-0EN
Issued 03-07
Copyright
8001-9
Main pressure measuring port
B44
B42
330-1-05-00-29AA
A pressure sensor is mounted on the control valve and

the circuit pressure can be displayed on the monitor
(except for pilot pressure).
B42, Pump pressure sensor P1.
B44, Pump pressure sensor P2.
Pressure on each relief valve (except for pilot pressure)
can be confirmed on the monitor display.
Installing the pilot pressure test

point
a3 (M3)
330.1.05.00.29EE
Install a pressure test point (M3) on the port (a3) of the

pilot pump.
Lep SC4608001-0EN
Issued 03-07
Copyright
8001-10
Flow curve
Curve valid for a new pump
CI02C511
Lep SC4608001-0EN
Issued 03-07
Copyright
8001-11
Display on the "CHK1" monitor

display
N:
To access this screen: Select work mode H or S using

control (2).
I:
Pump negative pressure in MPa (B43 pressure

sensor).
ENG: Engine speed in rpm (B41 sensor).

Pump control current value.
Fan motor current value (when Travel Mode
switch ON).
WT:
Radiator coolant temperature.

Hydraulic oil temperature.
OT:
Intake air temperature (only when Travel Mode

switch ON).
Warming up the engine

1. Start the engine. The engine will have warmed up
in 10-15 minutes.
2. Run the engine until the message "Auto warm up"

disappears from the display monitor.
CM00E001
Press simultaneously on the travel speed control (1)

and on the work mode selector control (2) as shown
above until the diagnostic screen CHK1 appears
(3 seconds).
CH
K
MODE II H
ENG
2000
rpm
P1:
Warming up the hydraulic fluid

1. Display the "CHK1" monitor display.
2. Actuate 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.
P1
030.0
MPa
0300
mA
4. Repeat Steps 1 and 2 until hydraulic temperature

reaches 45-55C on display "CHK1".
P2
030.0
MPa
WT
0080
5. Actuate the boom, swing and travel controls in both

directions to warm up all the circuits to 45-55C.
03.00
MPa
OT
0055
P1 pump pressure in MPa
(Pressure B42 sensor)
Pressure checked
P2:
Boom raising
Dipper retracting and extending
LH and RH swing
LH travel
P2 pump pressure in MPa
(Pressure B44 sensor)
Pressure checked
Lep SC4608001-0EN
Raising - lowering boom

Dipper extending - retracting
Bucket opening - closing
RH travel
Issued 03-07
Copyright
8001-12
CHECKING AND SETTING PROCEDURE

Location of secondary relief valves
E
D
F
G
B
C
A
CI01N508
CI01N507
CI01N510
CI02C510
CS00M501
Tool used
Look nut
Adjusting
screw
Set pressure
Pressure for 1 turn of

the screw (or for 1
shim*)
Main relief (standard pressure)
22 mm
19 mm
314 bar (31.4 MPa)
213 bar (21.3 MPa)
Main relief (power boost)
32 mm
26 mm
343 bar (34.3 MPa)
257 bar (25.7 MPa)
Boom raising port secondary relief
17 mm
Hexagon
wrench
6 mm
363 bar (36.3 MPa)
212 bar (21.2 MPa)
Boom lowering port secondary

relief
22 mm
Hexagon
wrench
8 mm
245 bar (24.5 Mpa)
131 bar (13.1 MPa)
Dipper out port secondary relief
Dipper in port secondary relief
Bucket open port secondary relief
17 mm
Hexagon
wrench
6 mm
363 bar (36.3 Mpa)
212 bar (21.2 MPa)
Bucket close port secondary relief
Pilot circuit main relief
24 mm
Hexagon
wrench
6 mm
39 bar (3.9 MPa)
20 bar (2.0 MPa)
RH swing port secondary relief

41 mm
Hexagon
wrench
14 mm
293 bar (29.3 MPa)
48 bar (4.8 MPa)
xx bar (xx MPa)
xx bar (xx MPa)
Item
Description
LH swing port secondary relief
Reverse travel secondary relief
Forward travel secondary relief
Lep SC4608001-0EN
Issued 03-07
Copyright
8001-13
Main pilot system relief (H)
Main relief (A)
Test
Test
1. Connect a 0-100 bar pressure gauge to pressure

test point P3.
2. With the engine at full speed, select mode "S".
3. Operate and hold in position the dipper retracting

control (against cylinder stops).
3. Move the pilot cancellation lever to its low position.

4. With the attachment, swing and travel controls in
neutral, read the value on the pressure gauge: The
value should be 39 to 41 bar (3.9 to 4.1 MPa).
Adjustment
2. With the engine at full speed, select mode "S".
4. Read the pressure on the monitor display:
2
1
1. Loosen the lock nut and turn the valve adjusting

screw (H) until 39 to 41 bar (3.9 to 4.1 MPa) is
reached.
2. Tighten the lock nut while holding the adjusting
screw in position.
3. When the adjusting screw has been tightened,

check the pressure again and make sure there are
no leaks.
Checking the pilot accumulator

1. Raise the boom completely and extend the dipper.
2. Shut down the engine, with the starter key switch
on "ON".
3. Operate the boom lowering or dipper retracting
control several times consecutively.
4. The pressure in the accumulator should enable the
boom lowering or dipper retracting function to be
performed about six times.
APPROX.
2 SEC
8 SEC
1. Standard pressure
2. Power boost
When the dipper cylinder is against the stops, the
pressure is the standard value for 2 seconds, then
at the valve over-setting for 8 seconds before falling
back to standard pressure.
Pump
Standard pressure
2-stage relief level
P1-P2
309 to 319 bar

(30.9 to 31.9 MPa)
338 to 348 bar

(33.8 to 34.8 MPa)
NOTE: To read the higher pressure - 2-stage relief level

again, the control lever should be released, then operated against the cylinder stops.
Lep SC4608001-0EN
Issued 03-07
Copyright
8001-14
Setting the power boost pressure
Adjusting the standard pressure

NOTE: Carry out the procedure below only if the power
boost pressure is correct, otherwise carry out the power
boost pressure setting procedure.
2
1
330.1.05.00.29YA
1. Disconnect and plug the power boost pilot hose on

the main relief.
3
330.1.05.00.29XA
2. Using a wrench, hold the adjusting screw (3) in

position and loosen the lock nut (4).

the main relief.
3. Tight the adjusting screw (3) up to the stop.

4. Tighten the lock nut (4).

5. Start the engine and run it at maximum speed,
select mode "S".
7. Loosen the lock nut (2) and turn the adjusting
screw (1) until the power boost pressure is
reached.
NOTE: Tighten the screw (1) to increase the pressure.
Loosen the screw (1) to reduce the pressure.
8. Using a wrench, hold the adjusting screw (1) and
tighten the lock nut (2).
9. Check the pressure again. If the desired value is
not obtained, repeat steps 6 to 9.
10. Cary out the standard pressure setting.
Lep SC4608001-0EN

select mode "S".
5. Turn the adjusting screw (3) until the standard pressure is reached.
position and tighten the lock nut (4).
8. Stop the engine.
9. Reconnect the power boost pilot hose to the main
relief.
Issued 03-07
Copyright
8001-15
Attachment control valve secondary

reliefs
(B, C, D, E, F and G)
NOTE: If the excavator is equipped with safety valves
on the boom and the dipper, secondary reliefs (B) and
(D) are not fitted or are overset. In this case it is necessary to set the pressures on the reliefs (B1-B2 and D1)
mounted on the safety valves.
NOTE: The attachment main reliefs are set to a higher
pressure than the main relief valve. To check or set the
attachment main reliefs, the main relief must be overset.
NOTE: Since the pressure of the boom lowering valve is
lower than the main relief, there is no need the overset
the main relief (Steps 1 to 4 and 15 to 19).
Checking and setting the pressure

2
8. Read the pressure on the monitor display, the pressure should be:
Boom raising
P1-P2
Boom lowering
P2
Dipper in
P1-P2
Dipper out
P1-P2
Bucket opening
P2
Bucket closing
P2
3635 bar
(36.30.5 MPa)
2455 bar
(24.50.5 MPa)
3635 bar
(36.30.5 MPa)
3635 bar
(36.30.5 MPa)
3635 bar
(36.30.5 MPa)
3635 bar
(36.30.5 MPa)
9. Carry out Steps 10 to 14 only if one of the attachment secondary reliefs has to have its pressure set.
Otherwise go on to Step 15.
3
4
1
CS01K554
330.1.05.00.29YA

the main relief.
3. Tighten the adjusting screw (1) 180.
select mode "S".
7. Operate and hold in position the corresponding
attachment control (against the cylinder stops).
10. Using a wrench, hold the adjusting screw (4) of the

secondary relief concerned in position and loosen
the lock nut (3).
11. Operate and hold in position the corresponding
attachment control (against the cylinder stops).
12. Turn the adjusting screw (4) of the secondary relief
concerned until the correct pressure is obtained.
15. Using a wrench, hold the adjusting screw (1) of the
main relief concerned in position and loosen the
lock nut (2).
17. Turn the adjusting screw (1) until the correct standard pressure of the main relief concerned is
obtained.
Lep SC4608001-0EN
Issued 03-07
Copyright
8001-16
Adjustment
19. Check that the standard pressure of the main relief

is correct, otherwise carry out Steps 15 to 19 again.
20. Stop the engine.
21. Reconnect the power boost pilot hose to the main

relief.
22. If the value is not correct, loosen the lock nut (1)
and turn the pressure setting screw (2) to adjust the
pressure. Tighten to increase the pressure,
untighten to decrease. When the pressure is correct, hold the screw (2) and tighten the lock nut (1).
Reset the control valve main relief (A).
Swing port secondary relief

(I, J)
CS99B596
(I) RH swing port secondary relief

(J) LH swing port secondary relief
Test
1
330.1.05.00.29AD1
CD00E143
1. Carry out Steps 1 to 5 in "Checking".
1. Disconnect the connector (green) from the swing

cancellation solenoid valve (Y1).

3. Slowly operate the swing control lever to the right

and gradually increase the engine speed to full
speed to make sure that the swing is locked.
3. Start the engine and select mode "S".

4. Switch on the swing brake control on the instrument
panel (indicator lamp ON).
5. Slowly operate the swing control lever to the right
and gradually increase the engine speed to full
speed to make sure that the swing is locked.
6. Repeat Step 5. for the LH swing, the pressures
must be:
4. Turn the adjusting screw (2) until the standard pressure is reached.
Function
RH swing
P1
2934 bar
LH swing
P1
2934 bar
Lep SC4608001-0EN
(29.30.4 MPa)
(29.30.4 MPa)
Issued 03-07
Copyright
8001-17
Checking the pressure delivered by

the proportional valve
Port a4(G 1/4)
KTJ10480-C01
1. Connect a pressure test point and a 0-100 bar

pressure gauge to pump port G4.
3. With the engine at full speed (no load engine),
select mode "H" and then mode "S".
Secondary pressure (MPa)
Upper
Limit
Upper
Limit
Input current (mA)

Controlled line graph
330.1.05.00.29R1
H mode
S mode
Pressure
12.9 bar
(1.29 MPa)
20 bar
(2.0 MPa)
Intensity
490 mA
405 mA
Lep SC4608001-0EN
Issued 03-07
Copyright
8001-18
PROCEDURE FOR CHANGING OPERATION TYPE

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

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

A1: Arm out (move to S1)
A1: Arm out
A2: Arm in (move to S2)
A2: Arm in
B1: Bucket open
B1: Bucket open
B2: Bucket closed
B2: Bucket closed
V1: Boom down
V1: Boom down
V2: Boom up
V2: Boom up
S1: Swing left (move to A1)
S1: Swing left
S2: Swing right (move to A2)
S2: Swing right
000-8-02-01-07B
000-8-02-01-07B
Lep SC4608001-0EN
Issued 03-07
Copyright
8001-19
Old Mitsubishi type
Old Kobelco type
Adopted manufacturers: MITSUBISHI, NIKO.
Adopted manufacturers: KOBELCO, FURUKAWA.
Operation Levers
Operation Levers
V1
V1
A2
S1
S1
S2
B2
B1
A1
S2
B2
B1
A2
A1
V2
V2
CS00F530M
CS00F530K

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

V2: Boom up (move to A2)
S1: Swing left (move to B1)
S2: Swing right (move to B2)
B1: Bucket open (move to S2)

B2: Bucket closed (move to S1)
S1: Swing left (move to B1)
S2: Swing right (move to B2)
000-8-02-01-07B
Lep SC4608001-0EN
Issued 03-07
Copyright
8001-20
NOTES
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Lep SC4608001-0EN
Issued 03-07
8002
Copyright
Section
8002
OF THE HYDRAULIC RESERVOIR
CNH
Lep SM4608002-0EN

Printed in France
September 2007
Copyright
8002-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
HYDRAULIC RESERVOIR ............................................................................................................................................ 3
Removal ..................................................................................................................................................................... 3
Installation .................................................................................................................................................................. 4
Description ................................................................................................................................................................. 6
SPECIFICATIONS
See Section 1002.
Lep SM4608002-0EN
Issued 09-07
Copyright
8002-3
HYDRAULIC RESERVOIR
Removal
NOTE: The numbers within brackets refer to the figures
on pages 5 and 6.
STEP 1
STEP 8
Remove the screws (7) and the protective plate (8) on
top of the control valve.
STEP 9
Loosen the screws (9) located under the machine.
Open the side door on the right of the machine and
remove the two screws (10). Remove the screw (10)
located on the right of the fuel reservoir. Remove the
protective plate of the reservoir (11).
STEP 10
Loosen the circlips (12) and disconnect the hose (13)
under the hydraulic reservoir.
STEP 11
JS00163A1

Attach identification tags to the output hoses. Disconnect the hoses.
STEP 2
STEP 12

Remove the screws (14) and the retaining shims (15).
STEP 3
Attach a "DO NOT OPERATE" tag to the ignition key in
the cab.
STEP 13
Using a hoist, remove the hydraulic reservoir (1) from
the machine.
STEP 4
Remove the screws and the access panels under the
hydraulic reservoir (1).
STEP 5
Using a container of suitable capacity, drain the hydraulic reservoir (1), by removing the plug (2).
STEP 6
Remove the screws (4) on top and inside the front boot,
then remove the protective housing (3).
STEP 7
Remove the screws (5) and the protective plate (6) on
top of the hydraulic reservoir (1).
Lep SM4608002-0EN
Issued 09-07
Copyright
8002-4
Installation
NOTE: The numbers within brackets refer to the figures
on pages 5 and 6.
STEP 1
Using a hoist, position the hydraulic reservoir (1) on the
machine.
STEP 2
Install the screws (14) and the retaining shims (15) to
hold the hydraulic reservoir (1) to the machine undercarriage, tighten the screws to a torque, see the specifications. Install the drain plug (2).
STEP 3
Connect the hose (13) using the two circlips (12).
Tighten the nut.
STEP 4
Connect the output hoses taking help of the tags
installed during removal.
STEP 5
Install the reservoir protective plate (11) using screws
(9) and (10).
STEP 6
Install the protective plate (6) under the hydraulic reservoir using retaining screws (5).
STEP 7
Install the protective plate (8) under the control valve
using screws (7).
STEP 8
Install the protective housing (3) using screws (4), then
install the screw mask inside the front boot.
STEP 9
Fill the hydraulic reservoir, see the section "Filling the
reservoir" in the operator's manual and check for leaks.
STEP 10
Start the engine. Pressurise the hydraulic reservoir
then stop the engine. Check again for leaks.
STEP 11
Install the protective plate under the machine using
screws and flat washers.
Lep SM4608002-0EN
Issued 09-07
Copyright
8002-5
Hydraulic reservoir
12
13
15
14
1
2
12
HYDRAULIC RESERVOIR
PLUG
CIRCLIP
Lep SM4608002-0EN
13
14
15
HOSE
SCREW
SHIM
Issued 09-07
Copyright
8002-6
Description
Location
3
4
4
8
10
11
10
7
6
5
3
4
5
6
7
8
9
10
11
PROTECTIVE HOUSING
SCREW
SCREW
PROTECTIVE PLATE OF THE HYDRAULIC RESERVOIR
SCREW
PROTECTIVE PLATE OF THE CONTROL VALVE
SCREW
SCREW
PROTECTIVE PLATE OF THE RESERVOIR
Lep SM4608002-0EN
Issued 09-07
Copyright
8003
Section
8003
REMOVAL AND INSTALLATION OF THE MAIN
HYDRAULIC PUMP AND THE PILOT PUMP
CNH
Lep SM4608003-0EN

Printed in France
September 2007
Copyright
8003-2
TABLE OF CONTENTS
SPECIFICATIONS ........................................................................................................................................................ 3
SPECIAL TORQUE SETTINGS .................................................................................................................................... 3
MAIN HYDRAULIC PUMP ............................................................................................................................................ 4
Removal and installation ............................................................................................................................................ 4
PILOT PUMP ................................................................................................................................................................. 8
HYDRAULIC PUMP COUPLING .................................................................................................................................. 9
Cross-sectional view ................................................................................................................................................. 9
Removal and installation .......................................................................................................................................... 10
Lep SM4608003-0EN
Issued 09-07
Copyright
8003-3
SPECIFICATIONS
See Section 1002.

Screw (7) for fixing the main pump to the coupling flange (5) ..............................367 to 496 Nm (270.68 to 365.83 lbf-ft)
Screw (3) for fixing the coupling flange (5) to the engine ...........................................88 to 108 Nm (64.90 to 79.66 lbf-ft)
Screw (6) for fixing the coupling (9) to the shaft of the hydraulic pump (8) .....................................295 Nm (217.58 lbf-ft)
Screw (1) for fixing the coupling flange (2) to the engine flywheel ......................................................49 Nm (36.14 lbf-ft)
Nuts for fixing the circlip of the silencer..................................................................68.7 to 98.1 Nm (50.67 to 72.35 lbf-ft)
Silencer bracket fastening screw............................................................................68.3 to 76.3 Nm (50.37 to 56.28 lbf-ft)
Lep SM4608003-0EN
Issued 09-07
Copyright
8003-4
MAIN HYDRAULIC PUMP

STEP 4
STEP 1
JS00163A1

STEP 2
STEP 3
Remove the access panel (1) below the hydraulic

reservoir.
STEP 5
Put an appropriate container under the hydraulic
reservoir. Open the drain cock and drain the hydraulic
fluid. Close the cock.
Disconnect the battery ground (-) cable (1) from the

battery.
Lep SM4608003-0EN
Issued 09-07
Copyright
8003-5
STEP 6
STEP 8
A
1
B
CD02H004
Remove all the retaining screws (A) from the panel (B),
then remove the panel (B).
STEP 9
Remove the engine hood (1) then the protective grille

(2).
STEP 7
CD00F108
Remove the circlip (1) fastening the silencer pipe to the

turbocharger.
NOTE: All the engine and the exhaust system to cool
down before starting any disassembly.
A
CD02C147
Disconnect all the hoses from the quick coupling

control block (A). Remove the block (A) from the panel
(B).
Lep SM4608003-0EN
Issued 09-07
Copyright
8003-6
STEP 10
STEP 13
CD00F110
Remove the four retaining nuts from the silencer

circlips, then remove the two circlips.
NOTE: When installing, tighten the nuts to the torque
specified on page 3.
STEP 11
CD02H004
To facilitate proper installation, attach identification tags

to all hoses and electrical connections of the main
hydraulic pump and the pilot pump.
STEP 14
Remove the pipes, the hydraulic hoses and the
electrical connections. Seal all hoses and unions of the
main pump as well as those of the pilot pump.
STEP 15
Install an appropriate lifting apparatus on the hydraulic
pump. Do not leave any slack so that the pump can be
supported once the fastening screws of the pump are
removed.
STEP 16
1
Remove the retaining screws of the hydraulic pump.
CD00F111
Remove the silencer assembly (1) from the machine.
STEP 12

STEP 17
Remove the hydraulic pump from the motor and put it
away from the machine. Place the hydraulic pump on a
clean workbench using suitable brackets.
NOTE: Carry out the following step only if a new
hydraulic pump needs to be installed.
STEP 18
Remove the connections of the hydraulic pump that has
just been removed and install them on the new
hydraulic pump. Remove and install the connections
one after another to avoid improper installation of the
connections on the new hydraulic pump.
CD00F076
Remove the three retaining screws (1) from the silencer

bracket, then remove the silencer bracket.
NOTE: For installing the hydraulic pump, proceed in the

reverse order to that of removal. Replace all rings with
new rings.

Lep SM4608003-0EN
Issued 09-07
Copyright
8003-7
STEP 19
NOTE: Before carrying out any work with the machine,

operate the swing, travel and the attachment for five
minutes with the engine at idle speed. Check that there
are no leaks in the system, check the oil level in the
hydraulic reservoir. Top up if necessary, refer to Section
8001.
CD00E176
Remove the four screws and washers (1). Remove the

cover (2) and the O-ring from on top of the hydraulic
reservoir. Scrap the O-ring. Fill the hydraulic reservoir
with hydraulic fluid (see Section 1002) up to a level in
between the "high" and "low" marks on the visual
gauge. Install the cover with a new O-ring, fasten it
using four screws and washers (1).
Connect the ground (-) cable (1) of the battery.
STEP 20
NOTE: Always drain the air out from the hydraulic
pump before starting the engine. If the air has not been
drained out, the pump can get damaged. For the
procedure, see Section 8000.
Lep SM4608003-0EN
Issued 09-07
Copyright
8003-8
PILOT PUMP
STEP 5
STEP 1
NOTE: When installing, proceed in the reverse order to

that of removal. Replace the O-rings with new O-rings.
Bleed the hydraulic pump.
Refer to "Removal of the hydraulic pump" in this section

and carry out Steps 1 to 3.
STEP 2
hoses, connect a vacuum pump to the hydraulic
reservoir (see Section 8000). Start the vacuum pump.
STEP 3
NOTE: Stop the vacuum pump.

are no leaks in the system, check the level of oil in the
hydraulic reservoir, top up if necessary. Adjust the
hydraulic pump, refer to Section 8001.
2
1
4
3
CD02H004
Place an appropriate container under the pilot pump (1)

to recover the hydraulic fluid that could escape from
one of the disconnected hoses or from the hydraulic
pump when the pilot pump (1) has been removed.
Disconnect the hoses (2), (3) and (4). Plug the union
and the hoses.
STEP 4
Remove the pilot pump retaining screws and remove
the pilot pump.
Lep SM4608003-0EN
Issued 09-07
Copyright
8003-9
HYDRAULIC PUMP COUPLING

Cross-sectional view
A
9
2
6
7
5
3 4
CS02H583
1
2
3
4
5
SCREW
COUPLING FLANGE
SCREW
WASHER
PUMP FLANGE
Lep SM4608003-0EN
6
7
8
9
HUB RETAINING SCREWS

SCREW
HYDRAULIC PUMP
COUPLING HUB
Issued 09-07
Copyright
8003-10

NOTE: The numbers within brackets refer to the
schematic on page 9.
STEP 1
Remove the screws (3) and the washers (4) from the
coupling flange (5). Remove the assembly from the
hydraulic pump.
STEP 2
Remove the retaining screws (6) from the splined hub
(9), then remove the hub.
CS02H584
STEP 3
Disassemble the screws (1) from the coupling flange
(2) and remove the flange. Visually check the condition
of the coupling splines. Change them if necessary.
STEP 4
Remove the screws (7) and the coupling flange (5) from
the hydraulic pump (8).
NOTE: When installing the hydraulic pump coupling,
proceed in the reverse order to that of removal. Adjust
the position of the coupling by aligning the splined hub
(9) with the end of the pump shaft (arrows)
corresponding to the stop on the pump shaft. Assemble
and tighten the splined hub retaining screw (6).
Lep SM4608003-0EN
Issued 09-07
Copyright
Section

OF THE MAIN HYDRAULIC CONTROL VALVE
CNH
Lep SM4608004-0EN

Printed in France
September 2007
8004
8004
Copyright
8004-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
MAIN CONTROL VALVE ............................................................................................................................................... 3
SPECIFICATIONS
Weight of control valve .......................................................................................................................... See Section 1002
Adjusting the valves............................................................................................................................... See Section 8001

Control valve mounting on upperstructure frame ................................................ 333 to 392 Nm (245.61 to 289.12 lbf-ft)
Lep SM4608004-0EN
Issued 09-07
Copyright
8004-3
MAIN CONTROL VALVE

STEP 5
STEP 1
JS00163A

STEP 2
Remove the upper access panel retaining screws and

remove the panels.

NOTE: When installing, tighten the screws to torque

(see special torque settings on page 2) (apply
Loctite 262 on the threads).
STEP 3
STEP 6
STEP 7
Attach identification tags to all hoses, pipes and
electrical wires of the control valve. Disconnect and
seal the hoses and pipes. Seal the control valve
unions. Disconnect the electrical connections.
STEP 8
STEP 9
Disconnect the earth (-) cable (1) from the battery.
STEP 4
To prevent any fluid leaks when disconnecting
hydraulic lines, connect a vacuum pump to the
Install lifting rings in the threaded orifices on the top of

the control valve.
Lep SM4608004-0EN
Issued 09-07
Copyright
8004-4
STEP 10
NOTE: The following step is to be performed only if the

control valve has to be changed.
STEP 13
Remove the unions and manifolds from the control
valve which has just been removed and mount them on
the new control valve. Remove and install the unions
and manifolds one after another to make sure that they
are correctly installed on the new control valve.
the reverse order. Replace all seals with new seals.
are no leaks in the system, check the level of oil in the
hydraulic reservoir, top up if necessary. Adjust the
valves in the control valve (see Section 8001).
Install a lifting device on the control valve rings.
STEP 11
CS02J502
Remove the retaining screws (1) and washers from the

control valve.
(see special tightening torques on page 2).
STEP 12
Carefully raise and guide the control valve out of the

upperstructure frame. Move all the hoses and pipes out
of the way. Remove the control valve from the machine
and place it on suitable stands.
Lep SM4608004-0EN
Issued 09-07
Copyright
Section
8005
OF THE ATTACHMENT CYLINDERS
CNH
Lep SM4608005-0EN

Printed in France
September 2007
8005
Copyright
8005-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 2
PREPARATION BEFORE REMOVAL/INSTALLATION.................................................................................................. 2
BOOM CYLINDER .......................................................................................................................................................... 3
Description ................................................................................................................................................................. 3
Removal ..................................................................................................................................................................... 4
Installation .................................................................................................................................................................. 6
DIPPER CYLINDER........................................................................................................................................................ 8
Description ................................................................................................................................................................. 8
Removal ..................................................................................................................................................................... 9
Installation ................................................................................................................................................................ 11
BUCKET CYLINDER..................................................................................................................................................... 14
Description ............................................................................................................................................................... 14
Removal ................................................................................................................................................................... 15
Installation ................................................................................................................................................................ 17
SPECIFICATIONS
See Section 1002.
PREPARATION BEFORE REMOVAL/INSTALLATION

- Park the machine on hard, flat ground.
- Completely retract the bucket and dipper cylinder rods and lower the attachment to the ground.
- Release pressure in the hydraulic circuit and install a vacuum pump on the hydraulic reservoir (see Section 8000).
Lep SM4608005-0EN
Issued 09-07
Copyright
8005-3
BOOM CYLINDER
Description
4
2
4
6
3
4
1
8
7
5
6
3
8
9
2
1
CS02B563
1
2
3
4
5
NUT
SCREW
LOCKING BUSHING
SHIM
WASHER
Lep SM4608005-0EN
6
7
8
9
SCREW
SHAFT
BOOM CYLINDER
SHAFT
Issued 09-07
Copyright
8005-4
Removal
STEP 3
NOTE: The numbers within brackets in the following

steps refer to the boom cylinder schematic on page 3.
STEP 1
4
3
1
1
JS00579A
JS00577A
Disconnect the lubrication hose (A) from the boom cylinder.
Remove the nuts (1) and the screws (2). Remove the
screws from the shaft (9) and the locking rings (3).
Push the shaft far enough so that it does not intefere
with the removal of the boom cylinder. Remove the
shims (4) and the locking rings.
STEP 4
NOTE: Lift the cylinder carefully, the cylinder is heavy,

its weight has to be balanced with slings during lifting.
STEP 2
JS00580A
Install a support (A) in front of the boom cylinder. Lower

the front of the boom cylinder on the support.
JS00578A
STEP 5
Attach a suitable lifting device to the boom cylinder.

Use the total movement to get sufficient support during
removal of the boom cylinder.
JS00581A
Attach a sling (B) to hold the cylinder rod to the cylinder

barrel.
Lep SM4608005-0EN
Issued 09-07
Copyright
8005-5
STEP 6
STEP 10
Repeat steps 1 to 9 to remove the other cylinder.
STEP 7
Disconnect the hydraulic supply hoses (A) from the

boom cylinder.
STEP 8
Plug the hoses with plugs and the unions with caps.
STEP 9
6
5
7
B
A
Remove the screw (6) and the washer (5).

Remove the shaft (7), using a steel bar and hammer.
Carefully lift the boom cylinder and move it away from

the machine. Place the boom cylinder on suitable supports. Remove the sling that holds the cylinder rod to
the cylinder barrel.
Lep SM4608005-0EN
Issued 09-07
Copyright
8005-6
Installation
STEP 3
STEP 1
6
5
7
B
B
JS00586A
Attach a suitable sling (B) to the boom cylinder to hold

the cylinder rod to the cylinder barrel.
NOTE: Lift the cylinder carefully. The cylinder is heavy,
Install the shaft (7) using washers (5) and screws (6).
Using a strip thickness gauge, check that there is a
clearance of 1 to 3.5 mm (0.05 to 0.11 in) between the
mounting bracket and the mounting ring of the cylinder
barrel. If necessary, remove the screw, the shaft and
add one or more shim(s) as required in order to get the
correct clearance. Install the pin and the screw.
STEP 2
Using a suitable lifting device, lift the boom cylinder.

Align the boom cylinder with the mounting brackets of
the frame. Place a suitable support under the boom cylinder to support it.
Start the vacuum pump. Remove the plugs from the

hydraulic hoses (A) and the caps from the unions. Connect the two hydraulic supply hoses on the boom cylinder.
STEP 4
JS00590A
Lift the boom cylinder and align the rod end of the cylinder with the mounting ports of the boom.
STEP 5
Repeat steps 1 to 6 to install the second boom cylinder.
Lep SM4608005-0EN
Issued 09-07
Copyright
8005-7
STEP 6
STEP 8
A
9
Install the pin (9) and the shims (4).
JS00656A
Connect the lubrication hose (A) to the boom cylinders.
STEP 7
STEP 9
2
Remove the vacuum pump and bleed the air from the
boom cylinders (see Section 8000).
STEP 10
Check the hydraulic fluid level in the reservoir. Top up
as required.
STEP 11
Lubricate the linkages.
JS00592A
Install the locking bushings (3). Install the screws (2)

through the locking rings and the shaft. Using a set of
spacer rings, check that there is a clearance of 1 to 3.5
mm (0.05 to 0.11 in) between the mounting bracket and
the mounting ring of the cylinder rod. If necessary,
remove the screws and the pin and add or remove one
or more shim (s) as required to obtain the correct clearance. Install the pin and the screws. Install the first nut
(1) on the screw and tighten until the nut touches the
locking ring. Unscrew the nut by a quarter of a turn and,
using two wrenches, install the second nut (1) to lock
the first nut in position. Remove the sling from the boom
cylinder.
Lep SM4608005-0EN
Issued 09-07
Copyright
8005-8
DIPPER CYLINDER
Description
2
1
CS02B564
1
2
3
4
SCREW
WASHER
PIN
SCREW
Lep SM4608005-0EN
5
6
7
8
WASHER
PIN
DIPPER CYLINDER
SHIM
Issued 09-07
Copyright
8005-9
Removal
STEP 4

steps refer to the dipper cylinder schematic on page 8.
STEP 1
B
JS00586A
Attach a suitable sling (B) to hold the cylinder rod to the

cylinder barrel.
Place a wooden shim (A) under the dipper cylinder (8).
STEP 2
1
2
STEP 3
Remove the shaft (3) using a steel bar and hammer.
Lep SM4608005-0EN
Issued 09-07
Copyright
8005-10
STEP 5
STEP 10
STEP 6
6
5
A
4
Disconnect the two hydraulic supply hoses (A) from the
dipper cylinder.
STEP 7
Plug the hydraulic hoses with plugs and the unions with
caps. Stop the vacuum pump.
STEP 8
JS00599A
Disconnect the lubrication hose (A) from the dipper

cylinder.
STEP 9
Attach a suitable lifting device to the dipper cylinder.

Use the total movement to get sufficient support during
removal of the dipper cylinder.
Lep SM4608005-0EN
Issued 09-07
Copyright
8005-11
Installation
STEP 11
8
STEP 1
JS00602A
Carefully lift the dipper cylinder and move it away from

the dipper. Remove the shims (8). Place the dipper
cylinder on suitable supports.
STEP 12
JS00586A
Attach a suitable sling (B) to the dipper cylinder to hold

STEP 2
8
B
JS00586A
Remove the sling (B) that holds the cylinder rod to the
cylinder barrel.
JS00602A
Attach a suitable lifting device to the dipper cylinder, lift

the dipper cylinder and bring it in position. Align the
dipper cylinder mounting ports with the boom brackets
and install the shims (8).
Lep SM4608005-0EN
Issued 09-07
Copyright
8005-12
STEP 3
STEP 5
6
5
4
CS02B567
Install the shaft (6) using washers (5) and screws (4).
Using a set of spacer rings, check that there is a
clearance of 1 to 3 mm (0.03 to 0.11 in) between the
barrel. If necessary, remove the screw, the shaft and
add or remove one or more shim(s) (8) as required in
order to get the correct clearance. Install the pin and
the screw.

hydraulic hoses (A) and the caps from the unions.
Connect the hydraulic supply hoses on the dipper
cylinder.
STEP 6
STEP 4
JS00586A
cylinder barrel.
STEP 7
JS00604A
Connect the lubrication hose (A) to the dipper cylinder.
JS00606A
Align the dipper cylinder mounting ports with the dipper

ports.
Lep SM4608005-0EN
Issued 09-07
Copyright
8005-13
STEP 8
3
2
1
CS02B566
Install the shaft (3), the washer (2) and the screw (1).
Using a set of spacer rings, check that there is a
clearance of 4.5 to 5.5 mm (017 to 0.21 in) between the
rod. If necessary, remove the screw and the shaft and
add one or more shim(s) as required in order to get the
correct clearance. Install the pin and the screw.
STEP 9
dipper cylinder (see Section 8000).
STEP 10
as required.
STEP 11
Lep SM4608005-0EN
Issued 09-07
Copyright
8005-14
BUCKET CYLINDER
Description
4
3
11
6
12
6
9
7
9
4
13
9
7
1
8
12
6
9
10
13
5
10
2
1
1
3
CRPH06C012G
1
2
3
4
5
6
NUT
SCREW
SHAFT
SHIM
BUSHING
O-RING
Lep SM4608005-0EN
7
8
9
10
11
12
13
NIPPLE
LINK
SEAL
O-RING
BUCKET CYLINDER
COMPENSATOR
O-RING
Issued 09-07
Copyright
8005-15
Removal
STEP 2

steps refer to the bucket cylinder diagram on page 14.
2
1
STEP 1
A
12
JS00609A
Remove the nuts (1) from the screw (2) and remove the
screw from the compensator (12).
11
STEP 3
Place a wooden
cylinder (11).
shim
(A)
under
the
bucket

STEP 4
Attach a suitable sling (B) to the bucket cylinder to hold

Lep SM4608005-0EN
Issued 09-07
Copyright
8005-16
STEP 5
STEP 8
A
C
A
Start the vacuum pump. Disconnect the two hydraulic

hoses (A) from the bucket cylinder. Plug the hydraulic
hoses with plugs and the unions with caps. Stop the
vacuum pump.
B
Remove the screw (A) and the washer (B).
Remove the shaft (C) from the dipper.
STEP 9
A
STEP 6
JS00614A
Remove the grease hose.

NOTE: Remove the wooden shim when the bucket cylinder is raised.
Carefully lift the bucket cylinder and move it away from

the dipper. Remove the shims (A). Place the bucket cylinder on suitable supports.
STEP 10
STEP 7
B
JS00586A
Lift bucket cylinder, using a sling.
Lep SM4608005-0EN
cylinder barrel.
Issued 09-07
Copyright
8005-17
Installation
STEP 4
STEP 1
JS00586A
Attach a suitable sling (B) to the bucket cylinder to hold


hydraulic hoses (B) and the caps from the unions. Connect the hydraulic hoses to the unions of the bucket cylinder. Stop the vacuum pump.
STEP 5
STEP 2
Install the grease hose to the bucket cylinder.
STEP 6
Install the bucket cylinder on the dipper.
STEP 3
B
C
B
JS00586A
cylinder barrel.
With the cylinder and the shims in position, install the

shaft (C), the screw (A) and the washer (B). Using a set
of spacer rings, check that there is a clearance of 1 to 3
mm (0.039 to 0.11 in) between the mounting bracket
and the mounting ring of the cylinder barrel. If necessary, remove the screw, the shaft and add or remove
one or more shim as required in order to get the correct
clearance. Install the pin and the screw.
Lep SM4608005-0EN
Issued 09-07
Copyright
8005-18
STEP 7
11
12
Lift the bucket cylinder (11) to align the cylinder rod and
the compensators (12). Install the shims.
STEP 8
2
3
Install the pin (3) and the screw (2). Using a set of
spacer rings, check that there is a clearance of 1.5 to
2.5 mm (0.059 to 0.098 in) between the connecting rod
and the mounting ring of the cylinder rod. If necessary,
remove the screw and the shaft and add or remove one
or more shim(s) as required in order to get the correct
clearance. Install the pin and the screw. Install the first
nut (1) on the screw and tighten until the nut touches
the boss. Unscrew the nut by a quarter of a turn and,
using two wrenches, install the second nut (1) to lock
the first nut in position.
STEP 9
bucket cylinder (see Section 8000).
STEP 10
as required.
STEP 11
Lep SM4608005-0EN
Issued 09-07
Copyright
Section
8006
8006
OF THE HYDRAULIC SWIVEL
CNH
Lep SM4608006-0EN

Printed in France
September 2007
Copyright
8006-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 2
HYDRAULIC SWIVEL ..................................................................................................................................................... 3
Removal and installation ............................................................................................................................................. 3
SPECIFICATIONS
Weight ................................................................................................................................................... See Section 1002

Capscrews for retaining locking bar ...................................................................................................... See Section 1002
Capscrews for retaining hydraulic swivel outer sleeve on upperstructure ............................................. See Section 1002
Lep SM4608006-0EN
Issued 09-07
Copyright
8006-3
HYDRAULIC SWIVEL
STEP 5
STEP 1
2
JS00163A1
Park the machine on flat, hard ground. Lower the

attachment to the floor.
STEP 2
1
CI00F500
Release pressure in the hydraulic system and release

pressure in the hydraulic reservoir (see Section 8000).
Remove the retaining hardware (1) from the lower

plates (2) then remove the plates.
STEP 3
CT07A009
Disconnect the earth cable (1) from the battery.
STEP 4
To prevent any fluid loss when disconnecting hydraulic
lines, connect a vacuum pump to the reservoir (see
Section 8000).
Lep SM4608006-0EN
Issued 09-07
Copyright
8006-4
STEP 6
STEP 11
1
3
2
CS02C504
CD02C137
To facilitate installation, attach identification labels to all

the hydraulic swivel hoses (outer and inner).
STEP 7
Remove the retaining screws (1), the locking bar (2)

and the retaining screws (3) from the hydraulic swivel
outer component.
NOTE: When installing, tighten to the torque specified

in Section 1002.
STEP 8
STEP 12
Raise the hydraulic swivel sufficiently to free it from its
bracket, so that it can be pivoted 90. Place the
hydraulic swivel on the ground.
NOTE: When installing, use the same procedure in the
reverse order. Replace all O-rings with new O-rings.
Before operating the machine, operate the travel, stop
the engine and check that there are no leaks. If there is
a leak, tighten the hose connections, check the level of
hydraulic oil in the reservoir and top up if necessary.
CS02C503
Disconnect the hoses from the hydraulic swivel. Plug

the hydraulic swivel hoses and orifices.
STEP 9
STEP 10
Connect suitable lifting equipment to the hydraulic
swivel. Do not leave any slack since the hydraulic swivel
has to be supported once the retaining screws are
removed.
Lep SM4608006-0EN
Issued 09-07
Copyright
Section
8007
8007

OF THE PILOT FUNCTION BLOCKS
CNH
Lep SM4608007-0EN

Printed in France
September 2007
Copyright
8007-2
TABLE OF CONTENTS
SPECIAL TORQUE SETTINGS .................................................................................................................................... 2
PILOT FUNCTION BLOCKS ......................................................................................................................................... 3
Travel pedal block ..................................................................................................................................................... 3
LH control lever ......................................................................................................................................................... 4
RH control lever ........................................................................................................................................................ 8
Swing shuttle block ................................................................................................................................................. 11
Cushion control valve .............................................................................................................................................. 12
Servo control and return manifold block .................................................................................................................. 12
6 solenoid valve block ............................................................................................................................................. 13

Control lever block lever locknut ......................................................................................................... 41 Nm (30.24 lbf-ft)
Lep SM4608007-0EN
Issued 09-07
Copyright
8007-3
PILOT FUNCTION BLOCKS

Travel pedal block
STEP 5
Attach identification tags on all hoses of the control

pedal block.
STEP 1
STEP 6
STEP 7
Provide for a container to recover any possible
hydraulic fluid leaks.
STEP 8
JS00163A

STEP 2
STEP 3
Disconnect the battery ground (-) cable (1) from the

battery.
STEP 4
lines, connect a vacuum pump to the hydraulic
reservoir (see Section 8000).
Remove and seal the hydraulic hoses (1). Remove the

junction joints (2), put plugs on the ports of the control
pedal, then discard the O-rings.
NOTE: When installing, replace all O-rings with new Orings.
STEP 9
Lep SM4608007-0EN
Issued 09-07
Copyright
8007-4
LH control lever
STEP 10

1
NOTE: Refer to page 3 and carry out Steps 1 to 4.
STEP 1
4
5
3
2
6
CD00G047
Remove the screws (1), then remove the lever (4).

Remove the screws (2), then remove the pedal (5).
Remove the screws (3), then remove the bracket (6).
Proceed in the same manner for the second pedal.
CD00G048
STEP 11
Lift the boot. Loosen and remove the four retaining

screws from the front upper portion of the control arm.
STEP 2
2
1
CD00E046
CD00G049
Loosen and remove the retaining screw (1) from the

function cancellation lever (2), then remove the lever.
Put the floor carpet away from the pedals. Remove the
screws (1) that fasten the control pedal block to the cab
floor, then remove the control pedal block.
that of removal. Start the engine and operate the
control levers. Stop the engine, check the circuit for
leaks and the hydraulic oil level in the reservoir, top up if
necessary.
Lep SM4608007-0EN
Issued 09-07
Copyright
8007-5
STEP 3
STEP 6
CD00G050
Loosen and remove the three retaining screws from the

inner cab access bar, then remove the access bar.
STEP 4
CD00G053
Loosen and remove the retaining screws from the arm

angle adjustment and function cancellation lever, then
remove the lever.
STEP 7
CD00G051
Label and disconnect the electrical connections (1),

remove the compartment control casing assembly (2).
STEP 5
CD00G054
Lift the upper portion of the control arm, label and

disconnect the electrical connections.
STEP 8
CD00G052
Loosen and remove the four retaining screws from the

rear upper portion of the control arm.
CD00G055
Loosen the locknut, unscrew the control lever and

remove the upper portion of the control arm.
NOTE: When installing, tighten the lock nut to torque
(see special torque settings on page 2).
Lep SM4608007-0EN
Issued 09-07
Copyright
8007-6
STEP 9
STEP 11
4
3
5
2
2
1
JD00764A
1
2
3
4
5
6
CD00G057
Loosen and remove the retaining screws from the lefthand side of the control arm.
CLIP
NUT
HANDLE
GROMMET
CONNECTOR
LEVER
STEP 12
Cut the clip (1) and discard it. Loosen the nut (2).
Unscrew and remove the handle (3) and the connector
(5) from the lever (6). Remove the nut (2) to remove the
grommet (4).
NOTE: Replace the grommet if it is damaged. The
grommet protects the unions from all types of
contamination.
STEP 10
CD00G058
Remove from the safety bar side, the rod (1) that links
the function cancellation lever to the safety bar.
STEP 13
1
CD00G056
Loosen and remove the upper retaining screws and the

two lower retaining screws from the front portion of the
control arm.
CD00G059
Loosen and remove the retaining screws from the plate

(1).
Lep SM4608007-0EN
Issued 09-07
Copyright
8007-7
STEP 14
STEP 18
2
2
1
1
CD00G060
Loosen and remove the screws that fasten the retaining

plate of the control lever (1) to the bracket (2).
STEP 15
CD00G062
Attach identification tags to all hoses of the control lever

block. Remove and seal the hydraulic hoses. Remove
the junction unions, put plugs on the ports of the control
lever block, then discard the O-rings. Loosen and
remove the retaining screws (1) from the plate (2).
STEP 19

leaks and the hydraulic oil level in the reservoir, top up
if necessary.
CD00G061
Take the control lever block (1) out from the bracket (2).
STEP 16
STEP 17
Lep SM4608007-0EN
Issued 09-07
Copyright
8007-8
RH control lever
STEP 3

STEP 1
1
CD00G068
Loosen and remove the retaining screws from the arm

angle adjustment lever.
STEP 4
CD00G065
CD00G069
CD00G066
Remove the trim panel (1) then remove the retaining

screws from the air-conditioning control box.
Lift the boot. Loosen and remove the retaining screws

from the front upper portion of the control arm.
STEP 5
STEP 2
CD00G070
CD00G067
Label and disconnect the electrical connection (1) then

remove the air-conditioning control box (2).
Lep SM4608007-0EN
Loosen and remove the retaining screws from the rear

upper portion of the control arm.
Issued 09-07
Copyright
8007-9
STEP 6
STEP 8
4
3
5
2
CD00G071
Lift the upper portion of the control arm, label and

disconnect the electrical connections.
STEP 7
2
1
JD00764A
1
2
3
4
5
6
CLIP
NUT
HANDLE
GROMMET
CONNECTOR
LEVER
Cut the clip (1) and discard it. Loosen the nut (2).
Unscrew and remove the handle (3) and the connector
(5) from the lever (6). Remove the nut (2) to remove the
grommet (4).
NOTE: Replace the grommet if it is damaged. The
grommet protects the unions from all types of
contamination.
STEP 9
CD00G072
Loosen the locknut, unscrew the control lever and

remove the upper portion of the control arm.
NOTE: When installing, tighten the lock nut to torque
(see special torque settings on page 2).
CD00G073
Loosen and remove the upper retaining screws and the

lower retaining screws from the front portion of the
control arm.
Lep SM4608007-0EN
Issued 09-07
Copyright
8007-10
STEP 10
STEP 13
STEP 14
STEP 15
CD00G074
Loosen and remove the retaining screws from the plate

(1).
STEP 11
1
CD00G077
Attach identification tags to all hoses of the control lever

block. Remove and seal the hydraulic hoses. Remove
the junction unions, put plugs on the ports of the control
lever block, then discard the O-rings. Loosen and
remove the retaining screws (1) from the plate (2).
STEP 16
CD00G075
Loosen and remove the screws that fasten the control

valve (1) retaining plate to the bracket (2).
STEP 12
1

leaks and the hydraulic oil level in the reservoir, top up if
necessary.
CD00G076
Take the control lever block (1) out from the bracket (2).
Lep SM4608007-0EN
Issued 09-07
Copyright
8007-11
Swing shuttle block
STEP 6

STEP 1
To make installation easier, attach identification tags to
all hydraulic hoses and electrical connections of the
shuttle block.
STEP 2
STEP 3
CD00G064

Remove the screws (1), then remove the shuttle block

(2) from its bracket.
STEP 4

that of removal. Start the engine, operate the control
levers, stop the engine, check the circuit for leaks and
the hydraulic oil level in the reservoir, top up if
necessary.
CD00G063
Remove and seal the hydraulic hoses, remove the

pressure detector, remove the junction unions, put
plugs on the ports of the shuttle block, then discard the
O-rings.
STEP 5
Lep SM4608007-0EN
Issued 09-07
Copyright
8007-12
Cushion control valve

Servo control and return manifold

block
STEP 1
Open the left-hand side doors.
STEP 1
STEP 2
To aid installation, put identification tags on all the

hydraulic hoses.
STEP 2
STEP 3
STEP 4
3
1
2
3
To aid installation, put identification tags on the
hydraulic hoses.
STEP 3
1
3
STEP 4
CS01N583
Remove and seal the hydraulic hoses.
Disconnect the hydraulic hoses from the cushion

control valve (1). Plug the hydraulic hoses and the ports
of the cushion control valve (1).
STEP 5
STEP 5
STEP 6
Remove the screws (1) then remove the block (2).

Remove the junction unions (3), discard the O-rings,
put plugs on the ports of the block.
STEP 6
Remove the screws (2) from the bracket and from the
cushion control valve. Remove the cushion control
valve.
necessary.
Lep SM4608007-0EN

necessary.
Issued 09-07
Copyright
8007-13
6 solenoid valve block
STEP 5
To aid installation, put identification tags on the

hydraulic hoses.
STEP 6
STEP 1
Open the left-hand side door of the machine.
STEP 7
STEP 2
Disconnect the hydraulic hoses connected to the

solenoid valve block. Seal the ports with caps and the
hoses with plugs.
STEP 8
STEP 9
Remove the screws and washers from the protective
housing.
STEP 3
Put the protective housing away to make it easier to
disconnect the connectors from the protective housing.
Loosen the retaining screws from the solenoid valve

block. Remove the screws and washers, making sure to
support it. Remove the solenoid valve block from its
bracket.
STEP 10
For proper installation of the connections, mark the
locations of the elbow unions. Fasten the solenoid valve
block in a vice. Remove the elbow unions and the
straight unions from the ports. Plug the solenoid valve
block ports with plugs to avoid any penetration of
foreign bodies.
STEP 4

that of removal. Start the engine. Energise several
times the solenoid valves (second speed selection,
swing brake control, power boost, pilot cushion control
cancellation, swing locking, negative control, boom
priority, pilot pressure). Stop the engine, check the
circuit for leaks and the hydraulic oil level in the
reservoir, top up if necessary.
Disconnect the connectors (1) by pressing on the

tongue fastener and then by pulling to separate them
(the connectors are identified by rings of different
colours).
Lep SM4608007-0EN
Issued 09-07
Copyright
8007-14
NOTES
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
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..........................................................................................................................................................................................
..........................................................................................................................................................................................
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..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
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..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
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..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
Lep SM4608007-0EN
Issued 09-07
Copyright
Section
8008
8008

OF THE SWING MOTOR
CNH
Lep SM4608008-0EN

Printed in France
September 2007
Copyright
8008-2
TABLE OF CONTENTS
SWING MOTOR............................................................................................................................................................. 3
+50
Swing motor retaining screws .....................................................................................................................295 -0
Lep SM4608008-0EN
Nm
Issued 09-07
Copyright
8004-3
SWING MOTOR
STEP 1
STEP 5
JS00163A

STEP 2
Remove the upper panel (2) retaining screws (1), then

remove the upper panel (2).

STEP 6
STEP 3
To facilitate installation, attach labels to all the hoses

and hydraulic unions which are disconnected during
removal.
STEP 7
STEP 8
6
5
3
Disconnect the earth (-) cable (1) from the battery.
STEP 4
lines, connect a vacuum pump to the hydraulic
reservoir (see Section 8000).
4
2
CD02E001
Attach identification tags to the hydraulic hoses.

Remove the hoses (1), (2), (3), (4), (5) and (6). Plug the
hoses and the unions.
Lep SM4608008-0EN
Issued 09-07
Copyright
8008-4
STEP 9
STEP 13
To prevent any contamination of the gear oil, cover the

reduction gear with a cloth or a suitable protection.
STEP 10

the reverse order.
STEP 14
See Section 8001 and adjust the swing motor
secondary relief valves.
NOTE: Before operating the machine, start the engine,
check the system for leaks and check the hydraulic oil
level in the reservoir, top up if necessary.
Connect a suitable lifting device to the swing motor.
STEP 11
1
2
To facilitate reassembly, make an alignment mark (1) on

the swing motor and on the reduction gear. Remove the
retaining screws (2) from the hydraulic swing motor.
(see special tightening torques on page 2).
STEP 12
Carefully lift the swing motor and move it away from the
swing reduction gear. Move the swing motor away from
the machine and place it on a clean workbench.
NOTE: When installing, apply Loctite 504 to the mating
surfaces between the reduction gear and the swing
motor.
Lep SM4608008-0EN
Issued 09-07
Copyright
Section
8010
MAIN HYDRAULIC PUMP
CNH
Lep SM4608010-0EN

Printed in France
September 2007
8010
Copyright
8010-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 3
REGULATOR ................................................................................................................................................................. 4
Exploded View ............................................................................................................................................................ 4
Sectional View ............................................................................................................................................................ 5
EXPLANATORY DIAGRAM OF REGULATOR OPERATION ........................................................................................ 7
HYDRAULIC PUMP ........................................................................................................................................................ 8
Exploded View ............................................................................................................................................................ 8
Cross-Sectional View .................................................................................................................................................. 8
Sectional View ............................................................................................................................................................ 9
PTO UNIT...................................................................................................................................................................... 11
Sectional View .......................................................................................................................................................... 11
Exploded View .......................................................................................................................................................... 12
REGULATOR DISASSEMBLY...................................................................................................................................... 13
HYDRAULIC PUMP DISASSEMBLY............................................................................................................................ 15
PTO UNIT DISASSEMBLY ........................................................................................................................................... 17
WEAR INSPECTION..................................................................................................................................................... 18
REGULATOR ASSEMBLY............................................................................................................................................ 20
HYDRAULIC PUMP ASSEMBLY.................................................................................................................................. 22
REGULATOR ADJUSTMENT....................................................................................................................................... 26
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-3
SPECIFICATIONS
See Section 1002.

Pump:
Screw (401)........................................................................................................................................................... 430 Nm
Screw (406)............................................................................................................................................................. 29 Nm
Plug (466) ............................................................................................................................................................... 36 Nm
Plug (468) ............................................................................................................................................................. 170 Nm
Plug (490) .............................................................................................................................................................. 8.8 Nm
Plug (492) .............................................................................................................................................................. 9.8 Nm
Pin (531) ............................................................................................................................................................... 430 Nm
Piston (532)........................................................................................................................................................... 430 Nm
Nut (808) ............................................................................................................................................................... 240 Nm
Regulator:
Screw (412), (413) .................................................................................................................................................. 29 Nm
Screw (436), (438) .................................................................................................................................................. 12 Nm
Plug (496) .............................................................................................................................................................. 8.8 Nm
Locknut (630) ........................................................................................................................................................ 160 Nm
Nut (801) ................................................................................................................................................................. 16 Nm
Nut (802) ................................................................................................................................................................. 19 Nm
PTO:
Screw (435)............................................................................................................................................................. 98 Nm
Plug (468) ............................................................................................................................................................... 74 Nm
NOTE: The numbers within brackets refer to the diagrams from page 4 to 12.
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-4
REGULATOR
Exploded View
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-5
VIEW C
HYDRAULIC CIRCUIT
SECTION A-A
SECTION B-B
Sectional View
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-6
Description
412 - HEX SCREW C.H.C
496 - PLUG
601 - CASING
611 - FEEDBACK LEVER
612 - LEVER (1)
613 - LEVER (2)
614 - CENTER PLUG
615 - ADJUSTING PLUG
621 - COMPENSATOR PISTON
622 - PISTON CASE
623 - COMPENSATOR ROD
624 - SPRING SEAT (C)
625 - OUTER SPRING
626 - INNER SPRING
627 - ADJUSTING RING (C)
628 - ADJUSTING SCREW (C)
629 - COVER (C)
630 - LOCK NUT
631 - PF SLEEVE
641 - PILOT COVER
643 - PILOT PISTON
644 - SPRING SEAT (Q)
645 - ADJUSTING RING (Q)
646 - PILOT SPRING
651 - SLEEVE
652 - SPOOL
Lep SM4608010-0EN
653 - SPRING SEAT

654 - RETURN SPRING
655 - SET SPRING
656 - BLOCK COVER
708 - O-RING
722 - O-RING
724 - O-RING
725 - O-RING
728 - O-RING
730 - O-RING
732 - O-RING
733 - O-RING
734 - O-RING
735 - O-RING
755 - O-RING
756 - O-RING
763 - O-RING
801 - NUT
814 - SNAP RING
836 - SNAP RING
858 - SNAP RING
874 - PIN
875 - PIN
876 - PIN
887 - PIN
897 - PIN
898 - PIN
924 - SET SCREW
925 - ADJUSTING SCREW (Q)
Issued 09-07
Copyright
8010-7
EXPLANATORY DIAGRAM OF REGULATOR OPERATION
Regulator function diagram
330.7.01.01.55I
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-8
HYDRAULIC PUMP
Exploded View
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-9
VIEW A
SECTION B-B
Sectional View
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-10
983 - PIN
981 - PLATE
954 - SCREW
953 - SCREW
901 - BOLT
886 - PIN
885 - PIN
824 - SNAP RING
808 - NUT
806 - NUT
792 - RING BACK-UP
789 - RING BACK-UP
774 - SEAL
732 - O-RING
728 - O-RING
725 - O-RING
724 - O-RING
719 - O-RING
717 - O-RING
714 - O-RING
710 - O-RING
702 - O-RING
548 - PIN
545 - BALL
544 - STOPPER 2
443 - STOPPER 1
541 - SEAT
535 - STOPPER (S)
534 - STOPPER (L)
532 - SERVO PISTON
531 - PIN
530 - TILTING PIN ASSEMBLY
492 - PLUG
Lep SM4608010-0EN
490 - PLUG
468 - PLUG
467 - PLUG
466 - PLUG
406 - SCREW
401 - SCREW
314 - VALVE PLATE (FRONT)
313 - VALVE PLATE (REAR)
312 - VALVE BLOCK
271 - PUMP CASING
263 - COVER SEAL (REAR)
261 - COVER SEAL (FRONT)
251 - SUPPORT
214 - BUSH
212 - SWASH PLATE
211 - SHOE PLATE
157 - SPRING
156 - SPHERICAL BUSH
153 - HOLDER PLATE
152 - SHOE
151 - PISTON
127 - BEARING SPACER
124 - NEEDLE BEARING
123 - ROLLER BEARING
114 - 1st GEAR
113 - DRIVE SHAFT (REAR)
111 - DRIVE SHAFT (FRONT)
012 - CYLINDER BLOCK
05 - PTO ASSEMBLY
04 - GEAR PUMP
Issued 09-07
Copyright
8010-11
PTO UNIT
Sectional View
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-12
Exploded View
115 - IDLE-SHAFT
117 - 2nd GEAR
118 - 3rd GEAR
125 - BEARING
126 - CYLINDRICAL ROLLER BEARING
128 - BEARING SPACER
262 - COVER
326 - GEAR CASE
Lep SM4608010-0EN
435 - FLANGE SOCKET

468 - PLUG
710 - O-RING
728 - O-RING
825 - LOCKING RING
826 - LOCKING RING
827 - LOCKING RING
886 - PIN
Issued 09-07
Copyright
8010-13
REGULATOR DISASSEMBLY
NOTE: The numbers within brackets refer to the drawing from page 4 and 5.
NOTE: Always keep the components from different
pumps separate from one another. During disassembly
of the pump, place the components on a rubber mat.
Handle the components carefully. Always mark the
position of the parts.
STEP 3
STEP 1
Remove the screws (412, 413) and then remove the

regulator.
After removing the cover (629) subassembly, remove

the outer spring (625), inner spring (626), and spring
seat (624) from the compensation section, and pull out
the adjusting ring (645), pilot spring (646), and spring
seat (644) from the pilot section.
The adjusting ring (645) can be easily removed by
pulling it out with an M4 bolt.
STEP 2
Remove the screws (438), and remove the cover (629).

The cover is assembled with an adjusting screw (628),
adjusting ring (627), lock nut (630), hexagon nut (801)
(802), and hexagon socket head stop screw (924). Do
not loosen these screws and nuts. Doing so changes
the adjusted pressure-flow setting.
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-14
STEP 4
Remove the screws (436 and 438) and remove pilot

cover (641).
After you remove the pilot cover, remove set spring
(655) from the pilot section.
STEP 7
Remove lever 2 (613). Leave pin (875) in.

Tweezers will facilitate the process.
STEP 5
Pull out pin (874) and remove feedback lever (611).

Remove stop ring (814) to remove spring seat (653),
return spring (654), and sleeve (651).
A snap ring (836) is fitted onto the sleeve (651).
Return spring (654) will pop out while removing stop
ring (814); do not lose it.
STEP 6
Push out pin (874) (pin dia. 4) from top with a fine
steel rod. Avoid hitting lever (1) (612) during this process.
STEP 8
Remove lever (1) (612). Leave pin (875) in.
STEP 9
Pull out pilot piston (643) and spool (652).
STEP 10
Pull out piston case (622), compensating piston (621),
and compensating rod (623). Now the regulator is completely disassembled.
Piston case (622) can be removed by pushing out the
compensating rod (623) from the opposite side of the
piston case.
NOTE: The components are small. Be very careful not
to lose them.
Remove locking ring (858), and remove support plug
(614) and adjusting plug (615).
Support plug (614) and adjusting plug (615) can be
easily pulled out if you use an M6 bolt.
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-15
HYDRAULIC PUMP DISASSEMBLY

NOTE: The numbers within brackets refer to the drawing from page 4 to 12.
STEP 4
NOTE: Always keep the components from different

pumps separate from one another. During disassembly
of the pump, place the components on a rubber mat.
Handle the components carefully, always mark the
position of the parts.
STEP 1
Remove the oil drain port plug (468) and drain the oil
from the pump casing (271).
Remove the plugs from both the front and rear pumps.
STEP 2
CD01G104
Place the pump horizontally with the regulator installation side facing down on the workbench and disconnect
the pump casing (271) and valve block (312).
When placing the pump with the regulator installation
side facing down, make sure that the workbench is
covered with rubber plates or equivalent to prevent
damage on the installation side.
When disconnecting the pump casing and valve block,
remove the 1st gear at the same time.
STEP 5
CD01G103
Remove the screws (412, 413) and remove the regulator.
STEP 3
Loosen the screws (401), which lock the swash plate
support (251), pump casing (271), and valve block
(312).
NOTE: If a gear pump and others are attached to the
back side of the pump, this procedure should be done
after disconnecting the gear pump and others.
CD01G105
Remove the cylinder (012) straight out from the pump

casing (271) toward the drive shaft (111), and remove
the piston subassembly (151), holder plate (153),
spherical bush (156), and cylinder spring (157) at the
same time.
Be careful not to damage the sliding surfaces of the
cylinder, spherical bush, shoes, and swash plate.
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-16
STEP 6
STEP 10
CD01G106
CD01G109
Remove the retaining screws (406) and remove the

seal cover (F) (261).
Remove the drive shaft (111) and 113) from the swash
plate support using a plastic mallet.
Remove the seal cover (F) with a bolt inserted in the

tapping hole for easier operation.
STEP 11
Handle with care when removing the seal cover (F), to

prevent scratches on the oil seal, which is attached to
the seal cover (F).
STEP 7
Remove the screws (406) and remove the seal cover
(R) (263).
STEP 8
CD01G118
Remove the valve plates (313 and 314) from the valve
block (312).
NOTE: They may be removed during the step 4.
STEP 12
CD01G107
Remove the front flange (251) by gently tapping it with

a plastic mallet. Discard the seal.
STEP 9
If necessary, remove the stopper (L) (534), stopper (S)

(535), servo piston (532), tilting pin (531) from the
pump casing (271) and needle bearing (124) from the
valve block (312).
When removing the tilting pin, use appropriate tools to
prevent damage to the top of the tilting pin.
Be careful not to damage the servo piston because
Loctite is applied to the connecting part of the tilting
pin and the servo piston.
The needle bearing should not be removed except
when it wears out.
Do not loosen the hexagon nut for the valve block and
swash plate support. Loosening the nut causes the
flow rate to change.
NOTE: Operation to be carried out in case of wear of
the piston or the control pivot.
CD01G108
Remove the shoe plate (211) and swash plate (212)

from the pump casing (271).
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-17
PTO UNIT DISASSEMBLY

NOTE: The numbers within brackets refer to the drawing from page 11 and 12.
NOTE: Disassemble PTO Subassembly following the steps described below after reading the entire disassembling
instructions.
STEP 1
STEP 6
Choose a work area for disassembly.

Choose a clean area.
Place rubber plates or cloth on a workbench to prevent scratches on the parts.
STEP 2
Remove debris or rust on the surface of pump with
cleaning oil or equivalent.
STEP 3
Remove the drain port plug (468) on the pump
casing and drain oil.
Drain oil from each plug on the front pump and the
rear pump.
STEP 4
Disconnect the flange socket and remove the gear
pump.
STEP 5
CD01G111
Disconnect the retaining ring (827), remove the idler

shaft (115), and pull out the 2nd gear (117), the roller
bearing (126), and the bearing spacer (128).
The roller bearing (126) cannot be removed from the
2nd gear (117).
STEP 7
CD01G110
Disconnect the screws (435) and remove PTO Subassembly.
CD01G112
Disconnect the retaining ring (825) and remove the 3rd

gear (118) and the ball bearing (125).
The ball bearing (125) cannot be removed from the
3rd gear (118).
NOTE: Installation is done in the opposite order of disassembly; however, keep in mind the following notes.
Make sure to repair the damaged parts and prepare
replacement parts beforehand.
Clean each part with solvent and install them after airblowing them.
When installing the sliding parts or bearings, make
sure to apply clean lubricant.
Replace sealing parts such as O-rings and oil seals
with new ones as a general rule.
Use torque wrenches for each mounting bolt and
plugs, etc.
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-18
WEAR INSPECTION
Standard dimension / Replacement of parts
recommended
Pump types
Location
Part to be replaced
K3V63,
K3V112,
K3V180,
K5V80
K5V140
Play between piston/bore (D-d)
0.028 /
0.056 mm
0.039 /
0.067 mm
0.043 /
0.070 mm
0.0375 /
0.078 mm
Replace the pistons or the

cylinder
Play at the shoe piston and the

guide (A)
0-0.1 / 0.3
mm
0-0.1 / 0.3
mm
0-0.1 / 0.3
mm
0-0.1 /
0.35 mm
Replace the pistons and the

piston retaining plate
Shoe thickness (t)
3.9 / 3.7
mm
4.9 / 4.7
mm
5.4 / 5.0
mm
5.4 / 5.0
mm
Replace the pistons and the

piston retaining plate
Free height of cylinder springs

(L)
31.3 /
30.5 mm
41.1 /
40.3 mm
47.9 /
47.1 mm
40.9 /
40.1 mm
Replace the springs
Height of the base plate and

the spherical bushing (H-h)
19.0 /
18.3 mm
23.0 /
22.0 mm
23.7 /
22.7 mm
23.7 /
22.7 mm
Replace the base plate and

the spherical bushing
K3V140
K5V200
Overhaul dimension of the cylinder, the distribution machined plate and the swash plate (machined surface)
Distribution machined plate (sliding contact surface)
Swash plate (at the plate)
Cylinder (sliding contact surface)
Irregularity of each surface
Standard roughness after

grinding
3-Z
Roughness of the surface at the wear limit
0.4 Z or lower (lapping)
D
L
Piston to cylinder bore
Free heigh of
cylinder spring (L)
clearance (D-d)
A
h
Piston, shoes, and

caulking section backlash (A)
Assembled height of holder plate

and spherical bush (Hh)
Shoe thickness (t)
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-19
STEP 1
Check for cracks, breakage and pitting on the shafts,
the cylinder block pump body.
STEP 2
Check for heavy wear, cracks, pitting, deep scratches,
rough areas on the plate, the piston housing, the pistons, and the control spools.
STEP 3
If one of these conditions is present, change the component.
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-20
REGULATOR ASSEMBLY
NOTE: Assembly is done in the reverse order of disassembly, taking into account the following instructions:
- Clean the components with detergent and dry them with compressed air.
- Tighten the screws and plugs to the recommended torque.
- Coat the moving parts with clean oil before assembling them.
- Install new seals and O-rings.
STEP 1
STEP 7
Select the location for assembling the regulator.

Find a clean location to assemble the regulator.
Place a rubber plate or cloth on the work surface so as
not to damage the parts.
Install pilot piston (643) into the negative control hole

on casing.
STEP 2
STEP 8
Ensure that the pilot piston slides smoothly without

engagement.
Assemble the compensation rod (623) into the compensation opening on the casing (601).
STEP 3
The pin that is press-fitted onto the lever 1 (612) is to
be inserted in the compensating groove. After you
insert the pin, install lever 1 onto the pin that is pressfitted onto the casing.
STEP 4
The pin that is press-fitted onto lever 2 (613) is to be

inserted in the groove on pilot piston. Insert the pin and
install lever 2.
STEP 9
SPOOL
FEEDBACK LEVER
Install spool (652) and sleeve (651) into the spool hole
on the casing.
Ensure that the spool and sleeve slides smoothly in
casing without engagement.
The spool must be oriented properly.
STEP 5
LEVER (1) SIDE
LEVER (2) SIDE (SUPPORT PLUG ADJUSTING

PLUG-SIDE
The pin that is press-fitted into support plug (614) goes

into the pin hole on lever 2. Install the support plug
(614) in this manner, and install locking ring (858).
STEP 10
Insert adjusting plug (615) and install the locking ring.
Ensure that you placed the support plug and the
adjusting plug in the respective holes.
Install feedback lever (611), align the pinholes on the

feedback lever, and insert pin (874).
At this point, move the feedback lever to see it is not

loose and there is no engagement.
You can facilitate the process by slightly inserting the

pin into the feedback lever beforehand.
The feedback lever must be facing the right direction.
STEP 6
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-21
STEP 11
STEP 14
Install return spring (654) and spring seat (653) into the
spool hole, and install stop ring (814).
Install cover (C) (629), into which you have already set
adjusting screw (628), adjusting ring (C) (627), lock nut
(630), hexagon nuts (801, 802), and set screw (924).
Then fasten the screws (438) to complete the assembly.
STEP 12
Install set spring (655) into the spool hole, install compensating piston (621) and piston case (622) into the
compensating hole, fit pilot cover (641), and fasten the
screws (436).
STEP 13
Install spring seat (644), pilot ring (646), adjusting ring

(Q) (645) into the pilot hole, then fit spring seat (624),
inner spring (626), outer spring (625) into compensating hole.
The spring seat must face the right direction.
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-22
HYDRAULIC PUMP ASSEMBLY

NOTE: Assembly is done in the reverse order of disassembly, however, the following instructions need to be
followed:
STEP 3
Respect the reference marks made during disassembly.

Lubricate the seals and the sliding parts.
Do not mix the parts of the front and rear pumps.
Use light Loctite when installing the control pivot.
STEP 1
CD01G115
Install the drive shaft (111) which are attached with the
roller bearing (123), bearing spacer (127) and stop ring
(824) on the swash plate support (251).
Do not hit the drive shaft with a hammer, etc.
Fit the outer ring of the bearing with a light strokes of
a plastic hammer and make sure that it is fit firmly
using a steel bar or equivalent.
STEP 4
CD01G113
Fit a new O-ring on the flange (1). Install the flange (1)
on the housing (2), respecting the reference marks
made during disassembly.
STEP 2
CD01G116
Assemble the seal cover (F) (261) with the pump casing (271) and secure them with the screws (406).
Apply grease lightly on the oil seal inside the seal
cover (F)
CD01G114
Place the pump casing with the regulator installation

side facing down, push down the tilting pin (531) of the
swash plate, and install the swash plate (212) on the
swash plate support (251) properly.
Make sure not to damage the oil seal when handling

it.
In case of a tandem pump attach the seal cover (R) or
seal cover (F) in the same way.
Make sure the swash plate moves smoothly by pushing it with finger tips of both hands.
Apply grease on the swash plate, swash plate support
or other moving part for the easy installation of the
drive shaft.
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-23
STEP 5
NOTE:
Assemble the pump on the rear side first.
Be careful not to mix up the orientation of the valve
block.
In case of the pump for clock wise rotation (viewed
from the input shaft side) position of the discharge
port :left side.
[position of the regulator : above]
In case of the pump for counter clock wise rotation
(viewed from the input shaft side) position of the discharge port :right side.
[position of the regulator port : above]
CD01G117
Assemble the piston cylinder subassembly (cylinder

block (141), piston subassembly (151 and 152),
retainer (153), spherical bush (156), cylinder spring
(157), spacer (158)) and insert them into the pump casing aligning the phase angle of the spline with the
spherical bush and cylinder.
Insert the 1st gear in the valve block beforehand, and

then couple the spline on the joint section of the drive
shaft.
STEP 8
STEP 6
CDIG103
CD01G118
Clamp the feedback pin of the tilting pin on the feedback lever of the regulator, install the regulator, and
fasten the screws (412 and 413).
Install the valve plate (313) on the valve block (312)

with the pins aligned.
Be careful not to mix up the regulator for the front use

and the rear use.
Be careful not to mix up the inlet and outlet direction

on the valve plate.
STEP 9
STEP 7
Install the drain port plug (468) to complete the procedure.
CD01G119
Install the valve block (312) on the pump casing (271),

tighten the screws (401) to the specifique torque.
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-24
TROUBLESHOOTING
1) General precautions
Following are countermeasures if you find abnormality during the operation of Kawasaki swash plate type axial piston
pump and motor.
General precautions are:
a) Considerations before starting repair.
Determine the characteristics of the abnormality before starting repair. Consider if the cause is originated from the
wrong circuit, failure of regulator, or attached valve. Double check that the problem involves the pump motor.
b) Before disassembling a system, make sure to read through the service manual. Conduct the disassembly in a correct
manner.
c) When disassembling a system, be careful not to allow dust to enter.
d) Parts are finished precisely. Be careful not to damage them when handling.
2) Troubleshooting for the pump main body
Pumps are often attached to a regulator, attached valves and attached pumps. It can be difficult to find the cause of the
problem. Checking the following points is useful to identify the problem area.
a) Filter check and drain oil check
Check the filter element. Check if a considerable amount of contamination is found.
It is normal that a little amount of metal dust originated from abrasion of the shoe or cylinders is seen. However, if the
amount of metal dust is extremely high in the filter, the shoe might be damaged. Check drain oil of inside the pump casing, as well.
b) Abnormal noise / abnormal vibration
Check for abnormal noise or abnormal vibration in the main pump. Examine if the sound repeats with regular frequency
such as, a hunching sound in the regulator or hunching sound of the valve relief.
If there is an abnormal vibration or sound, cavitation or damage inside the pump should be considered.
c) When using two pumps.
If piping uses two single pumps or two motors, change the pipe of each pump.
By changing the pipe, the problem can be identified whether it is caused by a pump failure or a piping failure after the
pump.
4) Perform pressure measurement.
If the problem is related to the controlling function, examine the problem areas using pressure measurement tools
instead of performing overhaul inspection.
Lep SM4608010-0EN
Issued 09-07
Copyright
8010-25
3) Overload on the motor
Causes
Countermeasures
Notes
Rotational speed-check if pressure is

set higher than expected value.
Set pressure at an expected value.
Check if the torque set of the regulator is high.
Recheck the regulator.
Refer to the regulator instruction

manual.
Damage and burning on the internal

parts of the pump.
Replacement of damaged parts.
Check filter and drain oil for abnormal dust from abrasion.
Wrong piping for the regulator.
Correct the regulator piping.
4) When pump flow rate declines significantly or discharging pressure does not increase.
Causes
Countermeasures
Notes
Faulty regulator.
Repair the regulator.

manual.
Damage and burning on the internal

parts of the pump.
Replacement of damaged parts.
Check filter and drain oil.
Attached faulty pump.
Replace damaged parts.
Disconnect the attached pump and

check the shaft coupling section.
Attached faulty valve.
Check attached valve. (Check espe- Refer to the attached valve instruccially puppets and seat springs.)
tion manual.
Wrong regulator piping.
Correct the regulator piping.
5) Abnormal noise / abnormal vibration

Causes
Countermeasures
Notes
Cavitation
Prevention of cavitation. Check

hydraulic oil for white turbidness.
Damage on the shoe

caulking area.
Replacement of piston shoe, shoe

plate or others.
Cracks on the cylinder
Replacement of the cylinder
Failure of pump installation
Reinstallation
Hunching of the regulator
Repair of the regulator

manual.
Hunching of the relief valve on the

attached valve
Repair the attached valve.
Refer to the attached valve instruction manual.
Lep SM4608010-0EN
- Boost pressure is too low.

- Failure of auxiliary pump.
- Air is drawn from the intake pipe.
- Intake resistance is too high.
Issued 09-07
Copyright
8010-26
REGULATOR ADJUSTMENT
Regulator type:
KR3H-9N5A
Revolution (min-1)
1980
Adjusting screw (954) Fastening (turns)
+1/4
Changes in flow (L/min.)
-7.6
+1/4
+7.6
+1/4
Changes in compensation control start pressure (MPa)
+1.8
Changes in input torque (N+m)
+91
Adjusting Maximum Flow
Adjusting Minimum Flow
Adjusting outer
spring
Adjusting Input
Power
Adjusting inner
spring
Adjusting Flow Controlling

Characteristics
Lep SM4608010-0EN
+2.17
Adjusting ring (627) Fastening (turns)
+1/4
+13
Changes in input torque (N+m)
+61
Set screw (924) Fastening (turns)
+1/4
Changes in flow control start pressure (MPa)
+0.17
+21
Issued 09-07
8011
Copyright
Section
8011
OF THE CONTROL VALVE
CNH
Lep SM4608011-0EN

Printed in France
September 2007
Copyright
8011-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
TOOLS REQUIRED ........................................................................................................................................................ 2
CONTROL VALVE .......................................................................................................................................................... 4
Description .................................................................................................................................................................. 4
Identifying the ports..................................................................................................................................................... 9
Disassembly.............................................................................................................................................................. 10
Inspection.................................................................................................................................................................. 14
Assembly .................................................................................................................................................................. 15
Troubleshooting ........................................................................................................................................................ 20
SPECIFICATIONS
Weight of control valve .......................................................................................................................... See Section 1002
Safety valve settings.............................................................................................................................. See Section 8001
TOOLS REQUIRED
1. Loctite 262
2. Torque wrench OEM 6472, OEM 6474 and OEM 6476
Lep SM4608011-0EN
Issued 09-07
Copyright
8011-3

Spool assembly
Screws (D) for the spools (3) to (7) and (8) to (11) .................................................................................... 24 to 26 Nm
Screw for the spool (49)............................................................................................................................. 19 to 22 Nm
Spool end (24) ........................................................................................................................................... 19 to 22 Nm
Load holding valve (37)
Plugs (A) and (F) ....................................................................................................................................... 28 to 30 Nm
Plug (H)...................................................................................................................................................... 14 to 18 Nm
Control valve assembly
Relief valve (38) ....................................................................................................................................... 93 to 108 Nm
Safety valves (39) ...................................................................................................................................... 78 to 88 Nm
Safety valves (40) .................................................................................................................................. 123 to 127 Nm
Relief valve (41) ..................................................................................................................................... 103 to 113 Nm
Retaining screws (56) of the control valve sections ............................................................................... 356 to 394 Nm
Plug (27) .................................................................................................................................................. 93 to 108 Nm
Plug (42) ................................................................................................................................................ 103 to 113 Nm
Plug (45) ................................................................................................................................................ 103 to 113 Nm
Plug (50) .................................................................................................................................................... 73 to 79 Nm
Plug (51) .................................................................................................................................................... 31 to 42 Nm
Plug (52) ................................................................................................................................................ 116 to 128 Nm
Plug (53) .................................................................................................................................................... 73 to 79 Nm
Plug (66) .................................................................................................................................................. 93 to 108 Nm
Plug (23) .................................................................................................................................................. 93 to 108 Nm
Plug (63) .................................................................................................................................................... 14 to 18 Nm
Cap retaining screws (34) and (54) ....................................................................................................... 103 to 113 Nm
Cap retaining screws (69) ................................................................................................................ 194.5 to 215.5 Nm
Cap retaining screws (12), (13), (63), (64), (72) and (73) ...................................................................... 103 to 113 Nm
Cap retaining screw (67)............................................................................................................................ 38 to 42 Nm
Plugs (91) .................................................................................................................................................. 49 to 59 Nm
Cap retaining screws (75) .......................................................................................................................... 58 to 64 Nm
Screw (55) ................................................................................................................................................. 58 to 64 Nm
Screw (68) .............................................................................................................................................. 14.4 to 16 Nm
Lep SM4608011-0EN
Issued 09-07
Copyright
8011-4
CONTROL VALVE
Description
52
51
1
54
39
52
34
68
69
39
66
54
70
66
54
40
54
55
52
52 54
51
38
47
55
47
56 81
54
39
39
75
76
38
56 81
CS02K558
Lep SM4608011-0EN
Issued 09-07
Copyright
8011-5
34
53
33
35
31
42
53
65
39
33
34
35
32
46
45
43
44
16
17 18
15
19
47
38
52
18
47
77
15
16
17
19
CS02K559
Lep SM4608011-0EN
Issued 09-07
Copyright
8011-6
33
60
34
36 35
33
31
37
35
34
70
35
31
71
66
33
71
69
52
31
64
34
35
66
97
33
29
64
91
52
35 34
52
33
39
28
31 52
48
47
35
31
53
34
35
33
39
40
36
33
60
37
CS02K562
Lep SM4608011-0EN
Issued 09-07
Copyright
8011-7
63
59
60
14
72
61
9
61
12
91
64
91
64
10
59
11
60
6
13
61
14
61
1
14
3
12
13
4
5
72
73
6
12
13
63
7
64
14
CS02K561
Lep SM4608011-0EN
Issued 09-07
Copyright
8011-8
63
41
41
53
51
39
52
28 29
52
67
23
22
48
49
62
20
52
51
29
24 21 25 27 26 50 30
CS02K560
Lep SM4608011-0EN
Issued 09-07
Copyright
8011-9
Identifying the ports

NOTE: Refer to Section 8001.
Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
Control valve housing

Control valve housing
Dipper spool 2
Bucket spool
Boom spool 1
Travel spool
Straight-line travel spool
Dipper spool 1
Option spool
Boom spool 2
Swing spool
Cap
Cap
O-ring
Check valve
Spring
Spacer
O-ring
Back up ring
Spool
Spring seat
Spring
Plug
Spool
Spring
O-ring
Plug
Check valve
Spring
Check valve
Check valve
Check valve
Spring
Cap
O-ring
Check valve
Load holding valve
Main relief
Safety valve
Safety valve
Safety valve
Plug assembly
Check valve
Spring
Plug
O-ring
Plug
O-ring
Spool
Plug
Plug
Plug
Plug
Screw
Screw
Screw
Lep SM4608011-0EN
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
75.
76.
77.
81.
91.
97.
O-ring
O-ring
O-ring
O-ring
Port plug
O-ring
Steel ball
Plug
Cap
Screw
Cap
Screw
O-ring
Cap
Cap
Screw
Plug
O-ring
Washer
Plug
Plug
Issued 09-07
Copyright
8011-10
Disassembly
STEP 3
NOTE: Remove the control valve from the machine,

see Section 8004.
59
61
General instructions
61
60
- Clean around the component to be removed and take

care to ensure that no foreign matter enters the
control valve.
61
- Label the parts removed and arrange them in a

manner that makes assembly easier.
- Since the spool is an integral part of the control valve
body and the sleeve, do not replace the spool.
60
NOTE: The numbers in brackets refer to the views on

pages 4 to 8.
Separating the sections

NOTE: Remove the sections only if required. If disassembly is required, place the control valve body in a
horizontal plane.
61
61
CS02K564
STEP 1
Remove the O-rings (59), (60) and (61).
Clean the outside of the control valve with a suitable

cleaning solvent to eliminate all traces of impurities,
grease and other foreign bodies. Dry, using low pressure compressed air.
Spool assembly
STEP 1
STEP 2
Loosen and remove the screws (54) that fasten the

caps (12) and (72) and remove the caps.
NOTE: If necessary, remove the complete plug assembly (91) and the O-ring (64).
81 56
STEP 2
Remove the O-rings (14) from sections (1) and (2) of
the control valve.
STEP 3
Remove the spools (3) to (7) and (8) to (11) from the
control valve body as sub-assemblies, taking care not
to damage them.
NOTE: Identify each spool so that they can be put back
in their respective housings during assembly.
STEP 4
Loosen and remove the screws (54) that fasten the
caps (73) and (13) and remove the caps.
NOTE: If required, remove the plug assembly (91) and
the plug (97).
81 56
CS02K563
Separate the two sections (1) and (2) from the control
valve by removing the screws (56) and the washers
(81).
Lep SM4608011-0EN
Issued 09-07
Copyright
8011-11
STEP 5
STEP 4
Remove the O-rings (14) from sections (1) and (2) of

the control valve.
Loosen and remove the spool assembly (49), then

remove the spring seats and the spring.
NOTE: To avoid abrasion of the spool surface during

disassembly of the spool assembly, use a vice with protective jaws and tighten the spool as close as possible
to the head in order to avoid any deformity. When the
threaded portion of the screw is coated with Loctite,
heat the head of the screw using an industrial drier until
removal becomes easy (normally the temperature
should be in between 200 and 250C). If this operation
causes the spring to be deformed and malfunction,
replace the spring.
Spool assembly (20)
STEP 6
Remove the spring (22).
NOTE: When removing the plug (23), make sure that

you do not drop parts which are under pressure from
the springs.
STEP 1
Loosen and remove the plug (23) and remove the
O-ring (62).
STEP 2
STEP 3
B
CS01K596
Remove the spool screws (D) on the spring side of the

spools (3) to (7) and (8) to (11). Remove the spring
seats (B) as well as the springs (C).
NOTE: In the spools (5) and (8), only remove the check
valves, the springs, the O-rings, the back up rings and
the plugs if it is necessary. If it is necessary to remove
them, heat the periphery of the spool in order to make it
easier to remove the plug.
Dipper load holding valve decompression

spool 1
STEP 1
Loosen and remove the screws (68) that fasten the cap
(67) and remove the cap (67).
STEP 2
Remove the O-ring (48) from the cap (67).
C
CS02K568
Remove the spool (A) from the sleeve (B). Extract the
sleeve (B) from the control valve body. Remove the piston (C), the O-ring (D) and the back-up ring (E).
Load holding block

NOTE: Be careful when removing components, some
parts are subject to spring pressure.
STEP 1
Loosen and remove the screws (54) and remove the
caps (34).
STEP 2
Remove the springs (33), the check valves (31) and
(32), and the O-rings (35) from the control valve body.
STEP 3
NOTE: The straight-line travel valve does not have

springs or check valves (see cross-section H-H).
Remove the spool (49) from the control valve body taking care not to damage it.
STEP 3
NOTE: For disassembly of the spool, refer to the

instructions previously cited for disassembly of spool
assemblies.
Lep SM4608011-0EN
Loosen and remove the screws (54) and remove the

caps (47).
Issued 09-07
Copyright
8011-12
STEP 4
Remove the load holding valves (67)
Remove the spacer (17) from the control valve body,

then remove the O-ring (18), the back-up ring (19) from
the spacer (17).

STEP 5
Remove the spring (33) and the check valve (31) from
the control valve body.
STEP 6
Loosen and remove the plug (52) (see cross-section CC).
STEP 7
STEP 1
Loosen and remove the screws from the load holding
valves (37) then remove the load holding valve.
STEP 2
Remove the O-rings (35) and (60) from the control
valve body.
STEP 3
STEP 8
Loosen and remove the plug (52) (see cross-section LL).
STEP 9
STEP 10
Remove the spring (33), the check valve (31) and the
O-ring (35) from the control valve body.
STEP 11
Loosen and remove the plug (45) and the O-ring (46).
STEP 12
Lep SM4608011-0EN
Issued 09-07
Copyright
8011-13

H
Valves
NOTE: Do not operate the valve components, as this
will affect the pressure, otherwise see Section 8001 for
the valve settings.
I
37
STEP 1
E
F
D
G
C
A
39
CS02C563
B
CS02K566

Loosen and remove the safety valves (39) from the control valve body. Remove the O-ring (A) from the safety
valve body.
STEP 2
STEP 1
Loosen and remove the plug (A) and remove the O-ring
(B).
38
STEP 2
Remove the spring (C), the spring seat (D) and the
spool (E).
STEP 3
CS02C560
Loosen and remove the plug (F) and remove the O-ring
(G).
Loosen and remove the relief valve (38) from the control valve body. Remove and discard the O-ring (A).
STEP 4
STEP 3
Disassemble the plug (H) and the O-ring (I).

NOTE: The steel ball (J) is a press fit, do not remove it.
42
CS01K600
Loosen and remove the plugs (42) and remove the

O-rings (A), (B) and (C).
Lep SM4608011-0EN
Issued 09-07
Copyright
8011-14
Auxiliary assembly
STEP 1
Loosen and remove the screws (54) from the caps (69)
and remove the O-rings.
STEP 2
Cleaning
Clean all the parts removed with clean oil. Dry with
compressed air and place each part on a clean sheet of
paper or vinyl for inspection.
Inspection
Loosen and remove the two plugs (66) and remove the
O-rings and the back up rings.
Inspect the surface of each part for scratches, abrasion

and other damage.
Plug assembly
STEP 1
1.
Check that there are no scratches or dents on the

non-return load check valve seat in the control
valve body and that there are no traces of rust or
contaminants.
2.
Check that there are no scratches or dents on the

periphery of the spool. Use an abrasive product to
remove any small scratches.
3.
Check that all sliding surfaces are moving freely.

Check for the absence of foreign matter in holes
and in grooves.
4.
Replace the springs in case of damage, deformity

or wear and tear.
5.
Replace all O-rings and back up rings with new

ones.
6.
After removing the caps and plugs, ensure that

there is no trace of paint at the level of the port of
the body or on the rim of the plug. (Any trace of
residual paint is likely to cause contamination that
could cause the system to malfunction and lead to
possible leaks).
Loosen and remove the plug (42) and remove the

O-ring (see cross-section J-J).
STEP 2
Loosen and remove the plug (63) from its port (see
cross-section Z-Z).
STEP 3
Loosen and remove the plugs (52) and remove the
O-rings.
Precautions before assembly

Before beginning assembly, check the quantity of the
parts, be sure of their final position and get all the
required tools ready.
Lep SM4608011-0EN
Issued 09-07
Copyright
8011-15
Assembly

spool 1
STEP 1
Spool assembly
NOTE: Take care not to apply too much Loctite, it could
seep through inside the spool and cause it to malfunction.
NOTE: If the spool (5) boom section 1 (opposite the
spring) and the spool (8) dipper section 1 (spring side)
have been removed for assembly, proceed in the following manner:
STEP 1
Apply Loctite 242 on the threaded portions of the spool

(49) and install the spring seats, the spring and the
spool end.
STEP 2
Install the spool in a vice with protective jaws. Tighten
the end of the spool to torque (see page 3).
Install the check valve and the spring in the spool,

install the back up ring and the O-ring on the plug.
Apply Loctite 242 on the threaded portion of the plug.
Install the spool in a vice with protective jaws and
tighten the plug at the end of the spools (5) and (8).
37
E
STEP 2
Apply Loctite 242 on the spring side on the threaded
portions of the spools (3) to (7) and (8) to (11). Install
the spool in a vice with protective jaws.
STEP 3
G
B
J
A
B
CS02K566
STEP 1
Install the plug (H) complete with a new O-ring (I).
CS01K596
Install the spring seat (B) the spring (C), spring seat (B)
on the screw (D) and tighten it on the spool to torque
(see page 3).
NOTE: Respect the positions of the O-rings and back

up rings. If installations are not carried out in the correct
order, the O-rings will be lacerated.
STEP 2
Install the plug (F) complete with a new O-ring (G).
STEP 3
Lubricate and install the spool (E) in the valve (37),
install the spring seat (D), install the spring (C), install a
new O-ring (B) on the plug (A). Install the plug (A) and
tighten to torque (see page 3).
Lep SM4608011-0EN
Issued 09-07
Copyright
8011-16
Valves
STEP 3
NOTE: Do not operate the valve components, as this

will affect the pressure, otherwise see Section 8001 for
the valve settings.
42
STEP 1
38
CS01K600
CS02C560
Install the main relief (38) equipped with an O-ring (A).

Tighten to torque (see page 3).
Install the plugs (42) complete with an O-ring (A), (B)

and (C). Tighten to torque (see page 3).
Load holding block

STEP 1
STEP 2
Install the O-rings (35) in the control valve housings,

dipper sections 1 and 2, boom sections 1 and 2, swing
and bucket sections, install the check valves (31) and
the springs (33).
STEP 2
A
39
CS02C563
Install the safety valves (39) complete with an O-ring

(A). Tighten to torque (see page 3).
Install the caps (34) and fasten them using screws (54).
STEP 3
Install the O-rings (35) in the travel control valve section, install the check valves (32) and the springs (33).
STEP 4
Install the caps (34) and fasten them using screws (54).
STEP 5
Install the O-ring (35) in the control valve straight-line
travel section housing.
NOTE: The straight-line travel valve is not equipped
with springs or check valves.
STEP 6
Install the cap (34) using screws (54). Tighten to torque
(see page 3).
Lep SM4608011-0EN
Issued 09-07
Copyright
8011-17
STEP 7
Install the check valve (15) and the spring (16) (see
cross-section I-I), install the spacer (17) complete with
an O-ring (18) and a back up ring (19).
up rings. If installations are not carried out in the correct
order, the O-rings will be lacerated.
STEP 8
Install the cap (47) using screws (54) and tighten to
torque (see page 3).
STEP 9
Install the O-ring in the option section (see cross-section E-E), install the check valve (31) and the spring
(33). Install the cap (34) and fasten it using screws (54).

up rings. Any wrong installation will cause lacerations
and external leaks.
STEP 3
Install the load holding valve (37) and fasten it using
screws (54). Tighten to torque (see page 3).
Auxiliary assembly
STEP 1
Install the caps (69) equipped with an O-ring (71) and
fasten them using the screws (70). Tighten to torque
(see page 3).
STEP 2
Install the plugs (66) complete with an O-ring and a
back up ring. Tighten to torque (see page 3).
STEP 10
Install the check valve (43) and the spring (44) on the
travel portion (see cross-section G-G). Install the plug
(45) complete with an O-ring (46). Tighten to torque
(see page 3).
STEP 11
Install the check valve (28) and the spring (29) on the
dipper portion 1 (see cross-section C-C). Install the
plug (52) equipped with an O-ring. Tighten to torque
(see page 3).
Load holding valve

STEP 1
Install the O-rings (60) and (35) on the control valve
dipper section 1 (see cross-section D-D) and boom
section 1 (see cross-section F-F).
STEP 2
Install the check valve (36) and the spring (33).
Lep SM4608011-0EN
Issued 09-07
Copyright
8011-18
Spool assembly (20)
STEP 3
STEP 1
D
Install the caps (73) and the caps (13) on the control
valve body and fasten them using screws (54). Tighten
to torque (see page 3).
STEP 4
Install the caps (12) and the caps (72) on the control
valve body and fasten them using screws (54). Tighten
C
CS02K568
Install the O-ring (D) and the back up rings (E) on the
sleeve (B). Install the piston (C) and the spool (A) in the
sleeve (B). Install the assembly in the control valve
body.
STEP 2
Install the spring (22) inside the plug (23) equipped with
an O-ring (62). Screw the plug on the control valve
body. Tighten to torque (see page 3).

spool 1
NOTE: Check the proper positioning of the caps (72)

and (73).
STEP 5
Install the plug (97) equipped with an O-ring on the
short cap of the option section (see cross-section E-E).
STEP 6
Install the plug (91) equipped with an O-ring (64) on the
long cap of the option section (see cross-section E-E).
STEP 1
Plug assembly
STEP 1
Install the spool assembly (49) in the control valve body

without forcing it.
Install the plug (42) equipped with an O-ring. Tighten to

torque (see page 3) (see cross-section J-J).
NOTE: Ensure that it is functioning properly by making

it slide manually.
STEP 2
STEP 2
Install the plug (63) in its port. Tighten to torque (see

page 3) (see cross-section Z-Z).
Install the cap (67) equipped with an O-ring (48) and

fasten it using screws (68). Tighten to torque (see page
3).
Spool assemblies (3) to (7) and (8) to (11)

STEP 1
Install the O-rings (14) on the control valve body.
STEP 2
Install the assembled spools (3) to (7) and (8) to (11) in
the ports of the control valve body.
NOTE: Ensure that the spool is installed in its original
port, install it without pressing too hard. After installing
the spool, make it slide manually to check its proper
functioning.
Lep SM4608011-0EN
Issued 09-07
Copyright
8011-19
STEP 3
Install the plugs (52) equipped with an O-ring. Tighten
NOTE: For installation of the control valve, see Section

8004.
Assembling the sections

STEP 1
59
61
61
60
61
60
61
61
CS02K564
Install new O-rings (61) and (60).
STEP 2
56 81
56 81
CS02K563
Assemble the two sections (1) and (2) using screws (56)
and washers (81). Tighten to torque (see page 3).
Lep SM4608011-0EN
Issued 09-07
Copyright
8011-20
Troubleshooting
Control valve in general
Problems
Spool does not
move.
Possible causes
Oil temperature has abnormally risen.
Remove any part causing resistance to oil

flow in piping.
Dirty hydraulic oil
Change oil and clean circuit at the same

time.
Over-tightening of piping port joints
Check torque.
Deformed valve housing by incorrect mounting
Loosen mounting bolts and check their condition.
Pressure is too high.
Check pressure by placing a pressure gauge

between pump and cylinder port.
Deformed spool
Replace valve as an assembly.
Damaged return spring
Replace damaged parts.
Dislocated spring or cap
Loosen cap first, and then center and

retighten it.
Temperature is not uniform inside the valve.
Warm up entire circuit.
Valve is blocked with dirt.
Eliminate dirt (flush).
Dislocated spring or cap
Check pilot valve and pilot relief pressure.
Lack of pilot pressure
Check seals in cylinder for damage.
Oil bypasses spool.
Check spool for damage.
Oil leakage from overload relief valve
Clean valve housing seats and relief valve

seats.
Oil leakage from anti-drift valve
Disassemble anti-drift valve and clean seat

section in each part.
If damage is found in seat section, replace
poppet or apply lapping to poppet together
with the section.
If any abnormality is found on anti-drift valve,
replace spool and sleeve at the same time
because they are press-fit.
Load check valve is blocked with dirt.
Disassemble and clean check valve.
Damage on poppet or seats in the check

valve
Replace poppet or apply lapping to poppet

and seats.
Load cannot be
held.
Load drops when

switching spool from
neutral to raised
position.
Countermeasures
Relief valve
Problems
Pressure does not
rise at all.
Possible causes
Main poppet, sleeve or pilot poppet sticks
and keeps open, or seats in valve are
blocked with dirt.
Unstable relief
pressure
Seats in pilot poppet are damaged.
Incorrect relief
pressure
Wear in seats due to dirt
Replace relief valve.
Piston or main poppet sticks.
Looseness in locknut and adjuster
Lep SM4608011-0EN
Countermeasures
Reset pressure and tighten locknut to specified torque.
Issued 09-07
Copyright
8011-21
Oil leakage
Damage on relief valve seats

Each part sticks due to dirt.
Replace O-rings for adjuster or in mounting
section.
Worn O-rings
Hydraulic system in general
Problems
Hydraulic system malfunctions

or does not operate at all.
Lep SM4608011-0EN
Possible causes
Countermeasures
Faulty pump
Check pressure or replace pump.
Faulty relief valve
Faulty cylinder
Repair or replace it.
High load pressure on pump
Check circuit pressure.
Cracks on the valve
Replace valve as an assembly.
Spool does not move with a complete

stroke.
Check spool for its movement.
Oil level in tank is too low.
Refill hydraulic oil.
Filter blockage in circuit
Clean or change filter.
Restricted circuit piping
Check piping.
Issued 09-07
Copyright
8011-22
NOTES
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Lep SM4608011-0EN
Issued 09-07
8012
Copyright
Section
8012
OF THE ATTACHEMENT CYLINDERS
CNH
Lep SM4608012-0EN

Printed in France
September 2007
Copyright
8012-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 2
SPECIAL TOOLS ............................................................................................................................................................ 4
CYLINDERS.................................................................................................................................................................... 6
Boom cylinder description .......................................................................................................................................... 6
Dipper cylinder description ......................................................................................................................................... 8
Bucket cylinder description ...................................................................................................................................... 10
Disassembly ............................................................................................................................................................. 12
Inspection ................................................................................................................................................................. 20
Assembly ................................................................................................................................................................. 21
SPECIFICATIONS
See Section 1002.
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-3

Boom cylinder
Piston nut..........................................................................................................................14 500 Nm (10 694.63 lbf ft)
Bearing retaining screw ...................................................................................1140 206 Nm (840.82 151.94 lbf ft)
Retaining clip retaining screw (15)...........................................................................31.5 5.9 Nm (23.23 4.35 lbf ft)
Piping retaining screw (5 A) ...................................................................................62.6 11.7 Nm (46.17 8.62 lbf ft)
Piping retaining screw (5 B) ...................................................................................56.9 10.7 Nm (41.96 7.89 lbf ft)
Hydraulic pipes retaining screw (4)......................................................................92.4 17.3 Nm (68.15 12.75 lbf ft)
Piston nut screw ....................................................................................................56.9 10.7 Nm (41.96 7.89 lbf ft)
Dipper cylinder
Bearing retaining screw ..................................................................................1560 294 Nm (1150.59 216.84 lbf ft)
Piping retaining screw (5) ......................................................................................62.6 11.7 Nm (46.17 8.62 lbf ft)
Hydraulic pipes retaining screw (4)......................................................................145 27.5 Nm (106.94 20.28 lbf ft)
Piston nut screw ...................................................................................................96.8 18.2 Nm (71.39 13.42 lbf ft)
Air bleeder (48) ........................................................................................................44.1 2.9 Nm (32.52 2.13 lbf ft)
Bucket cylinder
Bearing retaining screw ...................................................................................1140 206 Nm (840.82 151.94 lbf ft)
Piping retaining screw (5) ......................................................................................56.9 10.7 Nm (41.96 7.89 lbf ft)
Hydraulic pipes retaining screw (4)......................................................................92.4 17.3 Nm (68.15 12.75 lbf ft)
Piston nut screw ....................................................................................................56.9 10.7 Nm (41.96 7.89 lbf ft)
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-4
SPECIAL TOOLS
OEM 9797 Hydraulic cylinder repair bench
OEM 9798 Piston nut screw
PE.174E-220 Hydraulic/electric pump
OR
CAS 10918 Hydraulic cylinder repairing bench
OR
E/SCRS1 Hydraulic cylinder repair bench including:
- Repair bench
- Electric hydraulic motor-pump assembly
- Piston nut fastening wrench
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-5
OEM 9797
OR
E/SCRS1
PE-174E-220
OEM 9798
CAS10918
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-6
CYLINDERS
Boom cylinder description
28
26
20
44
24
27
21
23
43
22
42
15
16
47
11
25
17
41
7
10
8
19
34
35
36
33
37
5A
39
40
38
48
15
45
16
46
17
7
6
18
5B
44
8
43
9
CS02F584A
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-7
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
GREASE FITTING
NOT USED
NOT USED
SCREW
SCREW
WASHER
PIPE CLAMP
HYDRAULIC PIPE
O-RING
HYDRAULIC PIPE
O-RING
NOT USED
NOT USED
NOT USED
SCREW
LOCKING WASHER
RETAINING CLIP
SCREW
BEARING
SCREW
STEEL BALL
PISTON NUT
PISTON
SEAL
BACK-UP RING
SEALING RING
SEALING RING
SHIM
NOT USED
NOT USED
NOT USED
NOT USED
O-RING
BACK-UP RING
RING
SEAL
BACK-UP RING
WIPER SEAL
RETAINING RING
BUSHING
SEAL
CUSHION BUSHING
ANTI-DUST SEAL
BUSHING
CYLINDER ROD
CYLINDER BARREL
O-RING
BUSHING
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-8
Dipper cylinder description

6
5
7
33 34
19
15
16
17
48
39
40
35
37 36
44
43
18
38
5
10
11
6
22
5
6
23
26
20 21
44
24
43
8
47
27
42
41
17
45
46
16
15
CS02F586A
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
GREASE FITTING
NOT USED
NOT USED
SCREW
SCREW
WASHER
PIPE CLAMP
HYDRAULIC PIPE
O-RING
HYDRAULIC PIPE
O-RING
NOT USED
NOT USED
NOT USED
SCREW
LOCKING WASHER
RETAINING CLIP
SCREW
BEARING
SCREW
STEEL BALL
PISTON NUT
PISTON
SEAL
NOT USED
SEALING RING
SEALING RING
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
O-RING
BACK-UP RING
RING
SEAL
BACK-UP RING
WIPER SEAL
RETAINING RING
BUSHING
SEAL
CUSHION BUSHING
ANTI-DUST SEAL
BUSHING
CYLINDER ROD
CYLINDER BARREL
O-RING
BLEED SCREW
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-10
Bucket cylinder description
33 34
19
39
40
35
38
37 36
44
8
4
1
43
18
11
44
10
43
17
16
15
46
7
6
5
16
8
15
45
42
23
27
26
24
28
22
20 21
47
CS02F585
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
GREASE FITTING
NOT USED
NOT USED
SCREW
SCREW
WASHER
PIPE CLAMP
HYDRAULIC PIPE
O-RING
HYDRAULIC PIPE
O-RING
NOT USED
NOT USED
NOT USED
SCREW
LOCKING WASHER
RETAINING CLIP
SCREW
BEARING
SCREW
STEEL BALL
PISTON NUT
PISTON
SEAL
NOT USED
SEALING RING
SEALING RING
SHIM
NOT USED
NOT USED
NOT USED
NOT USED
O-RING
BACK-UP RING
RING
SEAL
BACK-UP RING
WIPER SEAL
RETAINING RING
BUSHING
NOT USED
CUSHION BUSHING
WIPER SEAL
BUSHING
CYLINDER ROD
CYLINDER BARREL
O-RING
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-12
Disassembly
STEP 3
NOTE: The boom, dipper and bucket cylinders are

basically identical in construction. What changes is the
hydraulic tube connections. Before installing the
cylinder in the repair stand, remove the hydraulic tubes.
Bucket cylinder
STEP 1
Boom cylinder
1. Remove the grease fitting (1) from the cylinder.
2. Remove the screws (4) and disconnect the hydraulic
tubes (8) and (10) from the cylinder.
3. Remove the screw (5), the washer (6) and the pipe
clamp (7). Remove the hydraulic tubes (8) and (10)
from the cylinder. Remove and discard the two Orings (9) and (11).

steps refer to the bucket cylinder diagram on page 10.
1. Remove the grease fittings (1) from the cylinder.
2. Remove the screws (4). Disconnect the hydraulic
pipes (8) and (10) from the cylinder.
3. Remove the screws (5), the washers (6) and the
pipe clamps (7). Remove the hydraulic tubes (8) and
(10) from the cylinder. Remove and discard the two
O-rings (9) and (11).
circlip (17).
NOTE: As an example, the repairing bench CAS 10918
is used.
STEP 4

circlip (17).
STEP 2
Dipper cylinder
1. Remove the screws (4) and disconnect the hydraulic
tubes (8) and (10).
pipe clamps (7). Remove the pipes (8) and (10) from
the cylinder. Remove and discard the two O-rings
(9) and (11).
circlips (17).
Lep SM4608012-0EN
JD00620A
Install suitable bushings on the cylinder head stock

chuck wings.
Issued 09-07
Copyright
8012-13
STEP 5
STEP 8
JD00621A
Tighten the bushing retaining screws.
JD00625A
Connect lifting equipment, if necessary, to the cylinder.

Position the cylinder in the repair stand with the rod end
of the cylinder at the head stock chuck. Loosen the
retaining screws of the tail stock chuck wings. When
positioning the cylinder rod end on the head stock
chuck wing, be sure that the chuck wing bushings are
centred in the rod bushing. Install the screw and nuts to
secure the cylinder rod end to the repair stand.
STEP 6
STEP 9
JD00623A
Install the stop pins on the boom tail stock.
STEP 7
JD00626A
On the cylinder repair stand, loosen the retaining

screws of the tail stock chuck wings. When positioning
the cylinder barrel end on the head stock chuck wing,
be sure that the bushings are centred in the cylinder
barrel bushing. Install the screw and nuts to secure the
cylinder barrel end to the repair stand.
JD00624A
Install suitable bushings on the cylinder tail stock chuck

wings. Tighten the retaining screws. Install the chuck
wings on the cylinder tail chuck. Tighten the locking
screws. Use the scale on the face of the chuck to aid in
centering the chuck wings.
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-14
STEP 10
STEP 12
JD00627A
JD00629A
Check and ensure that the chuck wings are centred on

the repair stand centre line using scales scribed on the
head and tail stock chucks.
Raise the cylinder barrel (46) support to support the

cylinder barrel. Tighten the nuts to lock the support in
position. Remove the lifting equipment.

steps refer to the boom cylinder, dipper cylinder and
bucket cylinder schematics on pages 6, 8 and 10.
STEP 13
STEP 11
JD00630A
To make reassembly easier, draw alignment marks on

the cylinder barrel (46) and the bearing (19). Remove
the screws (18).
JD00628A
Raise the cylinder rod (45) support to support the

cylinder rod. Tighten the nuts to lock the support in
position.
STEP 14
JD00631A
Place a container beneath the bearing and cylinder

barrel to catch any hydraulic oil that may still be inside
the cylinder. Start the hydraulic pump to remove the rod
from the cylinder barrel.
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-15
STEP 15
STEP 18
Connect lifting equipment, if necessary, to the cylinder

barrel (46) and remove from the repair stand.
D
B
STEP 16
A
C
A
JD00635A
Move the bearing (19) away from the piston (23).
Check that both stop bars (A) are installed to prevent

the head stock (B) chuck from turning. Remove the tail
stock chuck wings and install the wrench (C) on the tail
stock. Check that the wrench is centred on the chuck
and tighten the screws (D).
STEP 17
STEP 19
JD00632A
E
18
JD00633A
JD00636A
Push the head stock chuck towards the piston nut (22)
and, if necessary, remove the stop bars (A) and turn the
chuck until the wrench (E) engages the piston nut.
JD00634A
Remove the screws (20) from the piston nut (22). Turn
the cylinder rod and remove the ball (21).
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-16
STEP 20
STEP 22
JD00637A
Loosen the tail stock chuck screws. Tighten the wrench

nuts on the piston nut (22). Check that the wrench is
centred by using the scale on the chuck.
STEP 21
B
JD00639A
Start the hydraulic pump by pressing on the pedal to

loosen the piston nut. At the end of the stroke, remove
the two stop bars; if necessary, depress the rear of the
pedal to retract the cylinder rod just enough to enable
removal of the stop bars. Depress the rear of the pedal
to retract the cylinder rod to lower the toggle assembly
as far as possible on the circular plate then install the
stop bars.
STEP 23
Repeat Step 22, if necessary, until the piston nut has
been loosened.
STEP 24
A
JD00638A
Lower the toggle assembly (B) as far as possible on the

circular plate and install the stop bars (A).
JD00640A
Remove the piston nut (22) from the rod.
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-17
STEP 25
STEP 28
JD00641A
JD00644A
Remove the shim (28) from the rod.
Remove the two sealing rings (26) from the piston.
STEP 26
STEP 29
23
24 26
27
B
47
JD00642A
Remove the piston (23) then remove the bearing rod.
STEP 27
25
JS00645A
Install the piston (23) in a vice (A) with protective jaws

(B). Using a suitable tool, cut or break the seal ring
(24). Remove the seal ring and discard. Remove and
discard the two back up rings (25). Remove the piston
from the vice.
JD00643A
Remove the two sealing rings (27) from the piston.
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-18
STEP 30
JD00647A
JD00646A
Lep SM4608012-0EN
Use a suitable tool to remove the O-ring (47). Scrap the

O-ring.
Issued 09-07
Copyright
8012-19
STEP 31
34
38
37
33
35
40
36
39
JS00649A
JD00650A
JD00652A
Remove and discard the O-ring (33) and back up ring

(34). Remove and discard the back up ring (37) and the
seal (36). Remove and discard the buffer ring (A)
consisting of a ring (35). Remove and discard the wiper
ring (38).
STEP 32
40
JD00651A
39
JS00653A
With a suitable tool, remove the retaining ring (39) from

the bearing. Place the bearing on a press and with a
suitable drift, force the ring (40) out of the bearing.
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-20
STEP 33
Inspection
NOTE: The bucket cylinder does not incorporate a seal

on the cushion ring.
STEP 1
Remove and discard the seal (41) from the cushion ring
(42). Remove the cushion ring (42).
STEP 34
NOTE: Do the following step only if inspection indicates
that the bushings (44) require replacement.
Inspect the seals, U-rings, back up rings, and O-rings

prior to installation for any imperfections, tears, or other
damage. If the seals or the bushings are worn out or
damaged, replace the component(s). Ensure seals and
bushings are installed correctly with no twisting of the
seal or bushing. Install all new seals and rings wet with
hydraulic oil.
STEP 2
Check the sliding parts for wear or damage such as
scratches, dents, or bent parts. Small scratches can be
removed with a hone or crocus cloth.
44
43
STEP 3
Check for cracks in the welding or other damage.
STEP 4
Measure the internal diameter of the bushings (44). If
the internal diameter of the bushings is greater than the
specifications, replace the bushing(s).
JD00654A
43
44
JD00655A
Remove the four wipers (43) from the cylinder rod and
cylinder barrel. Use a suitable press and drift and
remove the two bushings (44) from the cylinder rod and
cylinder barrel.
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-21
Assembly
STEP 3

steps refer to boom cylinder, dipper cylinder and bucket
cylinder schematics in this section on pages 6, 8 and
10.
40
STEP 1
43
44
19
JS00659A
Using a suitable press and drift, install the bushing (40)

in the bore of the bearing (19).
JD00655A
STEP 4
43
40
44
39
JD00654A
Using a suitable press and drift, install the two bushings

(44). Install the four new wipers (43) with the lip side of
the wipers facing out.
JS00653A
Install the retaining ring (39) in the groove of the

bearing (19).
STEP 2
NOTE: The bucket cylinder does not incorporate a seal
in the cushion ring.
Install the cushion bushing (42) on the cylinder rod (45).
Install a new seal (41) in the cushion bushing.
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-22
STEP 5
JD00650A
Install a new O-ring (33) and back up ring (34). Install a

new wiper ring (38). Install a new U-ring (36) and back
up ring (37). Install a new buffer ring (A), consisting of a
ring (35).
JD00652A
JD00651A
38
37
34
35
33
40
36
39
JS00649A
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-23
STEP 6
STEP 8
JD00647A
JD00642A
Install the bearing (19) then the piston (23) on the

cylinder rod.
STEP 9
JD00646A
Coat a new O-ring (47) with clean hydraulic oil. Install

the O-ring in the centre groove of the piston.
STEP 7
JD00641A
Install the shim (28) on the piston rod behind the piston.
24
26
STEP 10
27
23
47
25
JS00645A
(A)
(B)
VICE
HARD WOOD
JD00640A
Place a tapered tool over the piston (23). Coat a new

seal ring (24) with clean hydraulic fluid. Slide the seal
onto the tool and install it in the groove of the piston on
top of the O-ring (47). Install two new back up rings
(25). Install four new sealing rings (26) and (27) in the
grooves of the piston.
Lep SM4608012-0EN
Install the piston nut (22) on the cylinder rod and hand
tighten.
Issued 09-07
Copyright
8012-24
STEP 11
STEP 13
Carry out Steps 4 to 12 of disassembly to install the

cylinder rod in the repair stand.
STEP 12
A
B
C
JD00660A
JD00637A
Remove the toggle assembly (A) and the cylinder (D)

on the RH side of the repair stand, by removing the
stop bars (B) and the pins (C). Install the toggle
assembly and cylinder (D) on the left side of the repair
stand. Operate the hydraulic pump by depressing the
foot pedal to extend the rod end of the hydraulic
cylinder to rotate the circular plate clockwise to tighten
the piston nut. At the end of the stroke, remove the two
stop bars; if necessary, depress the rear of the pedal to
retract the cylinder rod just enough to enable removal
of the stop bars. Depress the rear of the pedal to retract
the cylinder rod to lower the toggle assembly as far as
possible then install the stop bars. Repeat this step as
required to tighten the piston nut to torque (see
"Specifications").
JD00636A
Carry out Steps 19 to 21 of disassembly to install

wrench (E) on the piston nut (22).
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-25
STEP 14
STEP 16
JD00634A
JD00637A
Loosen the nuts to remove the wrench from the piston

nut (22). Move the repair stand support away from the
cylinder rod.
STEP 17
JD00633A
Install the steel ball (21) in the piston nut (22). Install
the screw (20) in the nut. Tighten the screws to torque
(see "Specifications").
STEP 15
JD00662A
Using suitable means of lifting, install the tube on the

repair stand in order to align the cylinder rod (45) and
the bearing. Install the tube and the bearing (19) by
aligning the markers.
20
21
JS00661A
(A) AWL
After tightening the screw (20) to the required torque,

caulk the screw at two places.
Lep SM4608012-0EN
Issued 09-07
Copyright
8012-26
STEP 18
STEP 21
Dipper cylinder
1. Install the circlips (17) on the cylinder, using
washers (16) and screws (15). Tighten the screws to
torque (see "Specifications").
2. Install the hydraulic pipes (8) and (10) on the circlips
(17), using clamps (7), washers (6) and screws (5).
Tighten the screws to torque (see "Specifications").
JD00630A
Install the screws (18) and tighten to torque.
STEP 19
Attach a suitable lifting device to the cylinder. Remove
the screws and chuck wings to free the cylinder from
the repair stand.
3. Install the two new O-rings (9) and (11) on the

cylinder. Connect the hydraulic pipes (8) and (10) to
the cylinder using the screws (4). Tighten the
screws to torque (see "Specifications").
4. Install the new O-ring (3) on the pipe (8). Install the
plug (2). Tighten the plug to torque (see
"Specifications").
5. Install the grease fitting (1) in the cylinder.
STEP 20
STEP 22
Boom cylinder
Bucket cylinder

1. Install the circlip (17) on the cylinder, using washers
(16) and screws (15). Tighten the screws to torque
(see "Specifications").
2. Install the two hydraulic tubes (8) and (10) on the
circlip (17), using clamps (7), washers (6) and
screws (8). Tighten the screws to torque (see
"Specifications").
3. Install two new O-rings (9) and (11) on the cylinder.
Connect the hydraulic pipes (8) and (11) to the
cylinders. Fasten the pipes using screws (4).
4. Install two new O-rings (3) on the pipes. Install two
plugs (2) and tighten the plugs to torque (see
"Specifications").
NOTE: The numbers within brackets in the following steps

refer to the bucket cylinder schematic on page 10.
1. Install the circlip (17) on the cylinder barrel, using
washers (16) and screws (15). Tighten the screws to
torque (see "Specifications").
2. Install the hydraulic pipes (8) and (10) on the circlip
(17), using clamps (7), washers (6) and screws (5).
3. Install the two new O-rings (9) and (11). Connect
the hydraulic pipes (8) and (10) to the cylinder and
fasten the pipes with screws (4). Tighten the screws
to torque (see "Specifications").
4. Install the grease fittings (1) in the cylinder.
5. Install the grease fitting (1) in the cylinder.
Lep SM4608012-0EN
Issued 09-07
Copyright
8013
Section
8013
OF THE CONTROL LEVERS
CNH
Lep SM4608013-0EN

Printed in France
September 2007
Copyright
8013-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
CONTROL LEVER ......................................................................................................................................................... 3
Description ................................................................................................................................................................. 3
STRUCTURE ................................................................................................................................................................. 4
FUNCTIONS .................................................................................................................................................................. 4
OPERATION .................................................................................................................................................................. 5
CONTROL LEVER ......................................................................................................................................................... 7
Disassembly ............................................................................................................................................................... 7
Inspection ................................................................................................................................................................. 10
Assembly ................................................................................................................................................................. 11
TROUBLESHOOTING ................................................................................................................................................... 5
SPECIFICATIONS
Torque settings
Orifice plate retaining screws ..................................................................................................................20.6 1.5 Nm
Universal joint on control lever ................................................................................................................47.1 2.9 Nm
Lock-nut on universal joint ......................................................................................................................68.6 4.9 Nm
Primary pressure
Maximum pressure 6.9 MPa
Secondary pressure
0 to 4.4 (Maximum control pressure) MPa
Allowable back pressure
Maximum 0.3 MPa
Rated flow
20 L/min
Operating inclination
19, 25 (single)
Mass
1.9 kg
Piping
To obtain better response, suitable piping is inner diameter 8, length 3 M. In addition,

the return oil should be directly returned to the tank to avoid the influence of back
pressure.
Lep SM4608013-0EN
Issued 09-07
Copyright
8013-3
CONTROL LEVER
Description
1
20
2
3
19
4
5
6
7
17
18
22
10
11
12
16
15
13
21
14
18
CRPH06B059G01
1
2
3
4
5
6
7
8
9
10
11
12
13
LOCK-NUT
PROTECTIVE BOOT
DISC
PUSH-ROD
PLATE
PLUNGER ASSEMBLY
O-RING
SPRING SEAT
SPRING
SPRING
SPOOL
CONTROL LEVER BODY
ORIFICE PLATE
Lep SM4608013-0EN
14
15
16
17
18
19
20
21
22
HEXAGONAL ALLEN-TYPE SCREW

O-RING
BUSHING
PUSH-ROD
SEAL WASHER
LIP-SEAL
UNIVERSAL JOINT
PLASTIC PIN
WASHER
Issued 09-07
Copyright
8013-4
STRUCTURE
The structure of a pilot valve is as shown in the assembly sectional drawing. The casing has openings along the vertical
axis, in which pressure reducing valves are integrated.
The pressure reducing valve section consists of spools (201), springs (241) for setting secondary pressure, return
springs (221), spring seats 1 (216) and washers 2 (217). The spring (241) for setting secondary pressure is configured
to obtain reduced secondary pressures of 0.49 to 0.98MPa (depending on models). The spool (201) is pushed against
the push rod (212) by the return spring (221).
As the push rod (212) is pressed down when the operating part of the handle is inclined, the spring seat 1 (216) is also
lowered at the same time, as a result, the settings of the spring for setting secondary pressure (241) change.
The casing (101) and port plate (111) have oil entry ports P (Primary pressure) and exit ports T (Tank), and the
secondary pressure is delivered from the ports 1, 2, 3 and 4.
FUNCTIONS
1) Basic functions
The pilot valve is a valve designed for controlling the strokes and directions of the control valve spool. This is achieved
by acting output pressures from the pilot valve on the end of the control valve spool.
To meet requirements for this function, the pilot valve is composed of the following segments:
Entry port (P) through which the hydraulic pump supplies oil
Multiple output ports (1, 2, 3 and 4) which are designed to apply pressure supplied from the entry port on the end of
spool in the control valve.
Tank port (T) which is required to control the output pressures described above.
Spool which connects an output port to the entry port or tank port.
Mechanical measures including springs which act on the spool described above in order to control output pressure.
2) Major component functions

The function of the spool (201) is to receive pressure oil supplied from the hydraulic pump at the port P, and by switching
the oil paths, to introduce the pressure oil at port P to output ports (1, 2, 3 and 4) or introduce to port P. It is the role of
the spring for setting secondary pressure (241) to determine output pressure by acting on this spool (201).
The push rod (212) is inserted in the plug (211) so that it can slide and change the deflection of the spring for setting
secondary pressures (241).
The return spring (221), regardless of the output pressure, acts on the casing (101) and spring seat (216) to return the
push rod (212) in the direction of zero displacement, ensuring that the spool (201) can return to its neutral position. This
return spring also functions as reaction spring, to give good operational responsiveness.
Lep SM4608013-0EN
Issued 09-07
Copyright
8013-5
OPERATION
This section describes the operation of pilot valves based on the Hydraulic Oil Circuit Drawing (Figure 1) and Operation
Description Diagrams (Figures 2 through 4). Figure 1 shows a typical usage of the pilot valve.
Figure 1. An example of pilot valve use
CRPH06B106E
1
2
3
PILOT VALVE
PILOT PUMP
MAIN PUMP
4
5
6
CONTROL VALVE
HYDRAULIC MOTOR
HYDRAULIC CYLINDER
1) When the handle is in neutral (Figure 2)

The force of the spring for setting secondary pressures (241), which
determines the output pressure on the pilot valve, is not applied on the
spool (201). Therefore, the spool (201) is pushed upward by the return
spring (221) (by the spring seat 1 (216)), the output ports (2, 4) are
connected with the port T. At this moment, the output pressure is equal
to the tank pressure.
216
241
221
201
000-7-06-01-15B
Lep SM4608013-0EN
Issued 09-07
Copyright
8013-6
2) When the handle is inclined (Figure 3)

As the push rod (212) is pushed in by inclining the handle, the spool
(201) (spring seat 1 (216)) moves downward and the port P and ports
(2, 4) are connected. As a result, the oil supplied from the pilot pump
flows into ports (2, 4), thus generating pressure.
212
216
201
000-7-06-01-15c
3) When the handle is held (Figure 4)

When the pressures at ports (2, 4) rise up to a pressure equivalent to
the force of the spring (241), which was set by inclining the handle, the
hydraulic force and the force of the spring are in balance. When the
pressures at ports (2, 4) are more than the set pressure, ports (2, 4)
and port P close and ports (2, 4) and port T open. When the pressures
at ports (2, 4) are less than the set pressure, ports (2, 4) and port P
open and ports (2, 4) and port T close. As a result, secondary
pressures are maintained constantly.
(T) Port T
(P) Port P
241
T
P
000-7-06-01-15d
4) Operation in ranges where the handle is greatly

inclined (depends on models)
In some models, when the handle is inclined more than a given degree, the upper end of the spool touches the bottom
part of the push rod bore and the output pressure remains equal to the port P pressure as connected.
What's more, if a structure where the spring seat and spring are integrated in the inside of push rod is used, when the
handle is inclined more than a given degree, the bottom part of the push rod bore contacts the spring, and the force of
the spring causes the secondary pressure gradient to change. Afterwards, the bottom part of the push rod bore
contacts the upper end of the spring seat; thus the output pressure remains equal to the port P pressure as connected.
Lep SM4608013-0EN
Issued 09-07
Copyright
8013-7
CONTROL LEVER
Disassembly
STEP 3
NOTE: The numbers in brackets in the following steps

refer to the schematic on page 3.
Always handle high precision parts with the greatest
care to prevent them being damaged by being knocked
or dropped. The components of the control lever may
rust due to contamination and humidity if they are left
without protection after disassembly. If work has to be
stopped, the components must be protected against
contamination or corrosion.
STEP 1
CD00G089
Remove the disc from the control lever.
STEP 4
CD00G087
Install the control lever in a soft-jawed vice. Remove the

protective boot.
STEP 2
CRPH06B110A
CD00G088
Remove the lock-nut from the control lever.

CRPH06B111A
Used the special tool 380001055.

Install two nuts on the universal joint and tighten them
fully. While holding the upper nut, turn the lower nut
anti-clockwise to unscrew the universal joint. Remove
the universal joint from the control lever.
NOTE: Carefully remove the universal joint to prevent
the plate and the push-rods, which are under pressure
from the springs, from flying out too quickly.
Lep SM4608013-0EN
Issued 09-07
Copyright
8013-8
STEP 5
STEP 7
CD00G091
CD00G093
Remove the plate.
Remove the spool assembly from the control lever.
NOTE: Mark the components removed in the following

steps to facilitate their insertion in the correct bore
during assembly.
STEP 8
STEP 6
CD00G094
Turn the control valve the other way up in the vice.

Unscrew and remove the six screws and the sealing
washers.
CD00G092
Depending on the condition of the return springs, the

friction of the O-rings can keep the plunger assemblies
in place in the body. In this case, use a flat screwdriver
to remove the plunger assemblies. Slide the
screwdriver into the external groove of the plunger
assembly, taking care not to damage the plunger
assembly. This must be done carefully, since the
plunger assembly can be thrown out suddenly, due to
the action of the return springs.
STEP 9
CD00G095
Remove the orifice plates and the O-ring from the body.
Scrap the O-ring.
Lep SM4608013-0EN
Issued 09-07
Copyright
8013-9
STEP 10
STEP 12
JD00774A
Remove the bushing from the body of the control lever.
STEP 11
CD00G098
Remove the spool (17) and the spring (18) from the
plunger assembly (6).
STEP 13
CD00G096
CD00G099
Remove the push-rod (4) from the plunger assembly

(6).
STEP 14
CD00G097
Press the spring down a few millimetres so as to free

the spool (11) from the spring seat (8). Separate the
spool (11) from the spring (10) and the washer (22).
Keep these components together for the reassembly
procedure.
Lep SM4608013-0EN
CD00G100
Remove and scrap the plunger assembly O-ring.
Issued 09-07
Copyright
8013-10
Inspection
STEP 15
Change all the seals and O-rings which have been

removed. Also change the washers on all screws which
have been removed.
STEP 1
Inspect the spools to ensure that the finish is not
damaged, that they are not bent or damaged in any
other manner. Make sure that the spool slides freely in
the control valve body bore. If defects are found,
change the entire control valve.
STEP 2
CD00G101
Remove and scrap the plunger assembly seal.
STEP 16
Cleaning the components:
1. Soak them in a suitable cleaning solvent until
contamination and oil are removed. Components can
be damaged if they are washed while they are still
contaminated.
2. Final washing: Immerse the components in a clean
receptacle containing a suitable cleaning solvent.
Impart a rotary motion to the receptacle so as to wash
the inner surface of the components as well. Dry the
components with a clean cloth.
NOTE: Never dry them with compressed air. Dust and
water contained in the air will damage and corrode their
surfaces.
3. Corrosion prevention: Apply an anti-rust product to
all the components.
JS00784A
Inspecting the controls. Change the components if

wear on the shaft pin and seal create play in the
controls greater than 2 mm.
STEP 3
If it is impossible after inspection of the parts to
determine the cause of an abnormal noise or a
reduction in primary pressure, change the control lever.
NOTE: Components can rust if left in the open air after

cleaning.
Lep SM4608013-0EN
Issued 09-07
Copyright
8013-11
Assembly
STEP 3
Carry out the assembly with the very greatest care. Do

not hit or force the components, since that will damage
them and cause seizure or oil leaks which would result
in impaired performance of the machine. Before
reassembly, remove all traces of metal particles or
foreign bodies from all components. Check that there
are no burrs on the components and remove them with
an oil stone. Replace all O-rings and thrust rings with
new components. Lubricate the O-rings and thrust
rings to prevent any damage during assembly. Tighten
all cap screws to the specified torque. Plug all orifices
with plugs to prevent any contamination of the control
lever by dust after reassembly.
A
CD00G103
Install the orifice plate (13) with the plastic pin (21) in
the orifice (A) in the control lever body.
STEP 1
STEP 4
JD00774A
Install the control lever body bushing.
STEP 2
CD00G104
Install the hexagonal Allen-type cap screws and the

sealing washers in the orifice plate (13). Tighten the
screws and retighten them alternately to a torque of
20.6 1.5 Nm.
STEP 5
CD00G102
Install the O-ring in the groove in the control lever body.
CD00G105
Assemble the spool assembly by installing the washer

(22), the spring (10) and the spring seat (8) on the
spool (11).
Lep SM4608013-0EN
Issued 09-07
Copyright
8013-12
STEP 6
STEP 8
CD00G106
CD00G108
Turn the control lever the other way up in the vice.

Install the return spring and the complete spool
assembly in the body, respecting the positions noted
during steps 5 to 7 (disassembly).
STEP 7
19
4
CI00G509
Install the lip seals (19) with their ends as shown above.
STEP 9
CD00G107
Install the O-ring on the plunger.
CD00G109
Coat the surfaces of the push-rod (4) with hydraulic

fluid and install it in the plunger (6).
Lep SM4608013-0EN
Issued 09-07
Copyright
8013-13
STEP 10
STEP 13
CD00G110
CD00G112
Install the spool (17) and the spring (18) in the plunger
(6).
Install the plate and retain it by means of the universal

joint.
STEP 11
STEP 14
CD00G111
CRPH06B110A
Install the plunger in the body. Depending on the

condition of the return springs, the friction of the
O-rings may keep the plungers in place in the body.
STEP 12
Repeat steps 5 to 11 for the other three bodies.
CRPH06B111A
Used the special tool 380001055.

Tighten the universal joint to a torque of 47.1 2.9 Nm
(34.7 2.1 lb-ft).
Lep SM4608013-0EN
Issued 09-07
Copyright
8013-14
STEP 15
STEP 17
CD00G113
Install the disc on the universal joint. Tighten until the

disc touches the four push-rods equally.
CD00G115
Place a few spots of grease on the push-rods.
STEP 18
STEP 16
CD00G116
CD00G114
Install the protective boot (2) on the control lever.
Install the lock-nut and tighten it to a torque of

68.6 4.9 Nm while holding the flats on the disc (3)
with a flat wrench.
Lep SM4608013-0EN
Issued 09-07
Copyright
8013-15
TROUBLESHOOTING
It is not easy to find the faulty part. The following table lists some possible problems. As repairs are not easy, refer to the
possible causes and countermeasures in the table.
The table below shows general symptoms/possible causes and countermeasures. However, as a machine's trouble is
generally caused not by a single faulty component but by other related components as well, it may be necessary to
apply measures other than those listed in the Table.
The table shown below does not necessarily include all possible causes and remedies. Therefore, the technician in
charge of repairs must further investigate problems and their causes as necessary.
Problem
Secondary pressure doesnot rise.
Causes
1.Lower primary pressure
Countermeasures
Ensure given primary pressure
2.Breakage and fatigue of secondary Replace with new one

pressure spring (241)
3.Abnormally large gap between Replace as a remote valve complete
spool (201) and casing (101)
assembly
Unstable secondary pressure
High secondary pressure
Lep SM4608013-0EN
4.Loose handle section
Disassemble/assemble and replace

handle section
1.Engaged sliding part
Repair engaged part
2.Fluctuations in tank line pressure
Direct return to oil tank
3.Entrapped air in piping
Bleed air by several operations
1.High tank line pressure
Direct return to oil tank
2.Engaged sliding part
Repair engaged part
Issued 09-07
Copyright
8013-16
NOTES
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Lep SM4608013-0EN
Issued 09-07
Copyright
Section

OF THE CONTROL PEDALS
CNH
Lep SM4608014-0EN

Printed in France
September 2007
8014
8014
Copyright
8014-2
TABLE OF CONTENTS
TORQUE SETTINGS ..................................................................................................................................................... 2
CONTROL PEDAL ......................................................................................................................................................... 3
Description ................................................................................................................................................................. 3
FOOT CONTROL ........................................................................................................................................................... 4
Disassembly ............................................................................................................................................................... 5
Inspection ................................................................................................................................................................... 6
Assembly ................................................................................................................................................................... 6
TORQUE SETTINGS
Cover retaining screws .............................................................................................................................53.9 to 63.7 Nm
Cam articulation pin locking screw (apply Loctite 241) ............................................................................13.3 to 16.1 Nm
Cap screw ....................................................................................................................................................3.9 to 5.8 Nm
Lep SM4608014-0EN
Issued 09-07
Copyright
8014-3
CONTROL PEDAL
Description
5
7
9
10
11
8
12
2
13
14
4
30
19
15
21
16
20
17
22
18
25
23
26
24
27
28
1
29
CS02A503
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
BODY
COVER
LOCKING SCREW
CAM SHAFT
BOOT
BUSHING
CAM
BRAKE NUT
SCREW
RETAINING SCREW
CAP
RETAINER
PLUG
O-RING
CONTROL ROD
Lep SM4608014-0EN
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
PISTON
SPRING
SPRING
SPRING SEAT
BALL
RETAINER
BUSHING
WASHER
SPRING SEAT
SPRING
COMPRESSION SPRING
WASHER
WASHER
SPOOL
PLUG
Issued 09-07
Copyright
8014-4
FOOT CONTROL
In neutral the foot control is a closed center hydraulic valve. The inlet oil from the pilot pump is blocked at both
regulator spools. The ports (1) and (2) are ported inside of the valve back to tank through a hole drilled
in the end, and a cross drilled hole in the regulator spool.
There are two springs for each regulator spool. The larger diameter spring provides the
return of the foot pedal and this spring is the resistance the operator feels in his foot.
Typically the return springs are stronger in foot control than in hand control.
If the dust cover under the foot control is torn, replace it. This will help prevent contamination from wearing
the U-seals on the push rods.
The gap between the push rod and the screw can be adjusted. A too tight adjustment can cause partial
actuation of the spool. The contact area between the push rod and the screw should be lightly lubricated
with grease.
As the foot control is moved, the push rod will push on both large and small diameter springs. The
smaller spring will push the spool and block of the return passage through the top meetering notches.
The bottom metering land will open a passage and allow pilot oil out to the work spool of the travel control spool.
As the travel spool moves and compresses the spring in the control valve, the pressure will increase and push up
on the bottom of the regulator spool. When the pressure of the oil pushing on the travel spool equals the
force of the spring behind the regulator spool the bottom metering land will block the pilot supply. When
the force of the spring equals the force of the pressure on the spool, the spool is in a balanced
position to maintain a proportional pressure with the compression of the spring.
The foot control must be moved further to compress the small spring and push the regulator spool
further to increase the pressure again.
The foot control is nothing more than an adjustable pressure regulator, and the operator provides adjustment.
Lep SM4608014-0EN
Issued 09-07
Copyright
8014-5
Disassembly
STEP 10
Always handle high precision parts with the greatest

care to prevent them being damaged by being knocked
or dropped. The components of the control pedal may
rust due to contamination and humidity if they are left
without protection after disassembly. If work has to be
stopped, the components must be protected against
contamination or corrosion.
Remove the O-ring (14) from the plug (13).

refer to the description on page 3.
Remove the springs (17), (18), the spring seat (19), the
ball (20), the retainer (21) and the bushing (22).
NOTE: Clean around the foot control pedal and take

care to prevent any foreign material entering the system.
STEP 13
STEP 1
Tighten the control pedal in a vice with protective jaws.
Remove the bellows (5).
STEP 2
Remove the locking screw (3) from the cam shaft.
STEP 3
Remove the cam shaft (4) using a drift, as well as the
ring (6).
STEP 4
STEP 11
Remove and label the control rod (15), as well as the
piston (16).
STEP 12
Remove the washer (23) and the spring seat (24).
STEP 14
Remove the spring (25) and the compression spring
(26).
STEP 15
Remove the washers (27) and (28).
STEP 16
Remove and mark the spool (29).
STEP 17
Remove the plug (30).
Identify the position of the cam (7) in relation to the

cover (2) and remove the cam.
STEP 5
Remove the brake nut (8) as well as the screw (9).
STEP 6
Remove the retaining screw (10).
STEP 7
Identify and remove the cover assembly (2).
NOTE: Repeat steps 1 to 7 for the other control pedal
body.
STEP 8
Remove the cap (11) and the retainer (12).
STEP 9
Lep SM4608014-0EN
Issued 09-07
Copyright
8014-6
Inspection
Assembly
STEP 1
NOTE: Immerse all parts in clean hydraulic fluid in

order to guarantee proper lubrication when installing
and restarting operation.
Check for cracks, distortion or blocking of the springs. If

any one of these defects is found, replace the spring.
STEP 2
Check the spools to ensure that their finish is not damaged, that they are not twisted, or chipped etc. Ensure
that the spools slide smoothly in the bore of the control
pedal body. If defects are found, change the entire control pedal.
STEP 1
Fasten the spool (29) in a vice equipped with soft jaws.
Install the following in the order shown : the washers
(27) and (28) and the compression spring (26).
NOTE: If the installation is performed incorrectly, this
can cause a change in the secondary pressure.
STEP 3
STEP 2
Check the sleeves and the clips to ensure that their finish is not damaged, that they are not twisted, cracked
or chipped. If any one of these defects is found, replace
the damaged part.
Carefully install the spool assembly (29), in the body

(1), install the spring (25), the spring seat (24) and the
washer (23).
STEP 4
NOTE: Repeat steps 1 and 2 for the three other ports of

the control pedal.
Check the bores for damage, internal damage of housings, or signs of internal wear at the level of the control
pedal. If the control pedal is damaged, replace the
entire assembly.
STEP 3
STEP 5
STEP 4
Discard all the O-rings and use new O-rings.
Install the piston (16) and the control rod (15) in the
body (1).
Install the bushing (22), then the ball (20), the retainer
(21), the spring seat (19) and the springs (17) and (18).
STEP 5
Install the O-ring (14) on the plug (13).
STEP 6
Install the retainer (12) in the plug (13).
STEP 7
Install the plug assembly (13) in the body (1).
STEP 8
Install the cap (11) on the plug (13).
NOTE: Repeat steps 1 to 8 for the other control pedal
port.
Lep SM4608014-0EN
Issued 09-07
Copyright
8014-7
STEP 9
Assemble the cover assembly (2) on the body (1) in its
original position. Fasten them using screws (10).
STEP 10
Install the screw (9) on the cam (7) using the brake nut
(8).
STEP 11
Assemble the cam (7) on the cover (2). Install the bushing (6) and the cam shaft (4). The surface of the cam
must be parallel with the cover surface (2).
STEP 12
Incline the cam and apply grease to the cam articulation and to the steel ball.
STEP 13
Assemble and tighten the screws (3) to the torque
STEP 14
Assemble the upper portion of the boot on the cam,
apply a humidity inhibitor in the cover groove to avoid
oxidation, then assemble the lower portion of the boot
on the cover.
Lep SM4608014-0EN
Issued 09-07
Copyright
8014-8
NOTES
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Lep SM4608014-0EN
Issued 09-07
Copyright
Section
8015
OF THE SIX SOLENOID VALVES BLOCK
CNH
Lep SM4608015-0EN

Printed in France
September 2007
8015
DISASSEMPLY AND ASSEMBLY
Copyright
8015-2
TABLE OF CONTENTS
SIX SOLENOID VALVES BLOCK................................................................................................................................... 3
Assembly Drawing ...................................................................................................................................................... 3
Theory of operation ..................................................................................................................................................... 4
Disassembly and assembly......................................................................................................................................... 5
Inspection.................................................................................................................................................................... 6
Troubleshooting .......................................................................................................................................................... 7
Lep SM4608015-0EN
Issued 09-07
Copyright
8015-3
SIX SOLENOID VALVES BLOCK

Assembly Drawing
Normally open type solenoid: S2
Normally closed type solenoid: SP, S1, S3, S4, S5
1.
BODY
12.
BINDING BAND
2.
SPOOL
13.
BINDING BAND
3.
SPOOL
14.
BINDING BAND
4.
SPRING
15.
BINDING BAND
5.
SPRING
16.
SOLENOID
6.
ADAPTOR
17.
O-RING
7.
SNAP RING
18.
SCREW
8.
NAME PLATE
19.
PLUG
9.
SPRING WASHER
20.
PLUG
10.
BINDING BAND
21.
RIVET
11.
BINDING BAND
Lep SM4608015-0EN
Issued 09-07
Copyright
8015-4
Theory of operation
The hydraulic fluid supplied from the port P is fed to the solenoid operated directional valves S1 to S5 when the valve
SP is energized. The hydraulic fluid is then fed to the ports C1 to C5 depending on whether or not the valves S1 to S5
are energized.
Electromagnetic selector valves S1, S3, S4 and S5:
Oil passes through when energized
Electromagnetic selector valve S2:
Oil passes through when not energized
Lep SM4608015-0EN
Issued 09-07
Copyright
8015-5
Disassembly and assembly

TIGHTENING
TORQUE
1.7 TO 2.0 Nm
O-RING
SO - NA - A022
TIGHTENING
TORQUE
1.7 TO 2.0 Nm
O-RING
SO - NB - P18
ELECTRONIC SELECTOR VALVE SP, S1, S3, S4, S5 => ITEM N (2) ASSEMBLY
ELECTRONIC SELECTOR VALVE S2 => ITEM N (3) ASSEMBLY
NOTE: Disassemble the valve with due attention not to

damage the O-ring and other parts, and store the parts
in a safe place.
If there is any flaw on the O-ring, replace it with a new
one.
Be careful to assemble the parts in the correct
orientation and without forgetting any of the parts.
When assembling, reverse the order of disassembling
and pay attention not to allow any foreign matters such
as dirt to get into the valve.
STEP 1
Remove the mounting bolts from the solenoid (C) and
remove the coil part.
(Tool: 3 mm Hexagon wrench)
STEP 4
Pry the snap ring (7) off by inserting a flat head
screwdriver or the like in the notch, and remove the
adapter (6).
STEP 5
Assemble the valve by reversing the order of
disassembling.
When tightening the core, pay attention not to damage
the edges of the flat portion of the core.
When mounting the adaptor, apply grease or other
appropriate lubricant to the O-ring (B) and pay attention
not to damage the O-ring.
STEP 2
Remove the tube, while paying attention not to damage
the edges of the flat portion of the core. However, if the
core is removed, replace the O-ring (A) with a new one.
(Tool: 23 mm spanner)
STEP 3
Take out the spools (2) and (3) and the springs (4) and
(5).
Lep SM4608015-0EN
Issued 09-07
Copyright
8015-6
Inspection
1.
Clean all parts using suitable cleaning solvent.

Immerse the solenoid valve housing in a cleaning
solvent for several minutes to dissolve dirt or other
foreign matter inside the solenoid valve housing.
Use low pressure compressed air to blow out any
foreign matter from interior of valve housing. Dry
parts using clean cloths.
2.
Inspect springs for cracks, distortion, or evidence

of permanent mis-setting. Replace a spring if any
of these defects are observed.
3.
Check for cracks, holes, deformities and other

signs of wear on the spools. Check that the spools
slide easily in the bores of the solenoid valve block.
If any of the above conditions is seen, replace the
solenoid valve block.
4.
Check that the internal threading is not worn out

and that the interior of the solenoid valve block
shows no signs of wear. If any of the above
conditions is seen, replace the solenoid valve
block.
5.
Measure the play between the spool groove and

the spool. The clearance =D - d must be
approximately 0.01 mm. If this is not the case,
change the solenoid valve block.
Lep SM4608015-0EN
Issued 09-07
Copyright
8015-7
Troubleshooting
Problem
Spool malfunction
Solenoid malfunction
Cause
Action
Foreign matters galling the spool
Remove the foreign matters, dismount the

valve, perform flashing, or replace the fluid.
Damaged parts or abnormal wear
Replace the valve.
Terminal disconnection
Insert the terminal.
Damaged coil
Replace the solenoid.
Broken lead wire

Fluid leakage to outside Loose bolts
Lep SM4608015-0EN
Tighten the bolt to the specified torque.
Damaged O-ring
Replace the O-ring.
Loose hex socket plug
Fasten the plug.
Issued 09-07
Copyright
8015-8
NOTES
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Lep SM4608015-0EN
Issued 09-07
Copyright
Section
8016
8016

OF THE CUSHION CONTROL VALVE
CNH
Lep SM4608016-0EN

Printed in France
September 2007
Copyright
8016-2
TABLE OF CONTENTS
SPECIAL TORQUE ....................................................................................................................................................... 2
CUSHION CONTROL VALVE ...................................................................................................................................... 3
Description ................................................................................................................................................................. 3
System drawing ......................................................................................................................................................... 4
Changed over to "SOFT" ........................................................................................................................................... 5
Arm OUT, operating ................................................................................................................................................... 6
Arm OUT, stopped ..................................................................................................................................................... 7
Changed over to "SOFT" ........................................................................................................................................... 8
Disassembly .............................................................................................................................................................. 9
Inspection ................................................................................................................................................................ 11
Assembly ................................................................................................................................................................. 11
SPECIAL TORQUE
Plug (7).................................................................................................................. 60 Nm to 70 Nm (44.25 to 51.63 lbf-ft)
Plug (8).................................................................................................................. 40 Nm to 50 Nm (29.50 to 36.88 lbf-ft)
Lep SM4608016-0EN
Issued 09-07
Copyright
8016-3
CUSHION CONTROL VALVE

Description
10 11 12 13
9
1
2
3
4
5
6
7
8
9
CONTROL VALVE HOUSING

SPRING
SPOOL
SPRING
SPOOL GUIDE
O-RING
FLOW RESTRICTION ADAPTATER
PLUNGER ASSEMBLY
O-RING
3
15
16
14
17
10
11
12
13
14
15
16
17
SPRING
SPRING GUIDE
O-RING
SPOOL
PLUG
SPOOL
SPOOL
SPOOL
NOTE: The cushion control valve can have a machined or moulded body. This manual deals with only the machined
body.
Lep SM4608016-0EN
Issued 09-07
Lep SM4608016-0EN
CUSHION SWITCH
SOLENOID VALVE
OPEN
CLOSED
ARM
CONTROL VALVE
REMOTE
CUSHION VALVE
THROTTLE a
THROTTLE b
CONTROL VALVE
ARM
THROTTLE d
THROTTLE c
LINE FILTER
CONTROL VALVE
BOOM
DOWN
UP
BOOM
CONTROL VALVE
REMOTE
PILOT GEAR PUMP
OIL TANK
HYDRAULIC
Copyright
8016-4
System drawing
Issued 09-07
Copyright
8016-5
Changed over to "SOFT"

Lever in Neutral
(1) The heat oil separated from the oil cooler line enters the cushion valve Port R.
(2) Then, the oil passes the reverse notch spool and goes through passages e and f. After passing the outer circumference of each cushion spool, the oil returns to the hydraulic oil tank via Port T of the cushion valve.
REVERSE NOTCH SPOOL
THROTTE b
THROTTE d
CUSHION SPOOL
THROTTE a
Lep SM4608016-0EN
THROTTE c
CUSHION SPOOL
Issued 09-07
Copyright
8016-6
Arm OUT, operating

(1) Pilot pressure enters the cushion valve at Port A from the remote control valve. As this pilot pressure enters the left
end of the cushion spool and the left end of the reverse notch spool, each spool moves to the right.
(2) The pilot pressure in the cushion spool enters the chamber g via the spool opening.
Then, the pressure passes the outer circumference of the reverse notch spool and goes into the control valve via Port C.
(3) The pilot pressure return oil from the control valve passes the outer circumference of the reverse notch spool and
goes into the chamber f via Port D. Then, the oil passes the outer circumference of the cushion spool and returns to the
hydraulic oil tank through Port T.
(4) At this time, as the reverse notch spool is switched over to the right, the passages e and f are closed to the heat oil
at the Port R. Therefore, the oil passes passage h and enters the left end of the cushion spool. The heat oil passes the
cushion spool throttles c and d and enters the remote control V via Port B. (The heat oil releases the remote control
valve).
TO CONTROL VALVE
FROM CONTROL VALVE
TO HYDRAULIC TANK
FROM
TO
REMOTE CONTROL
REMOTE CONTROL
VALVE
VALVE
THROTTE c
THROTTE d
CUSHION SPOOL
CUSHION SPOOL
TO HYDRAULIC TANK
ARM OUT, OPERATING
Lep SM4608016-0EN
Issued 09-07
Copyright
8016-7
Arm OUT, stopped

1) As the pilot pressure from the remote control valve stops, the reverse notch spool returns to the neutral position.
2) The cushion spool also returns to the neutral position and the pilot return oil from the control valve passes the throttles a and b. Due to the differential pressure between the front and back of trottle, the cushion spool is moved to the left
and as a result, the pilot return oil is restricted by trottle a.
3) Due to this restricting effect, the spool of the main control valve returns gradually to the neutral position.
FROM CONTROL VALVE
TO
REMOTE CONTROL
VALVE
THROTTE b
THROTTE a
CUSHION SPOOL
Arm OUT, stopped
Lep SM4608016-0EN
Issued 09-07
Copyright
8016-8
Changed over to "HARD"

When the cushion switch is changed over to "HARD" position, the solenoid valve is changed over. The pilot pressure
(3.92 MPa) from the gear pump enters the cushion valve at Port S.
All the cushion spools (for booms and arms, 4 positions in total) are forcedly changed over to the inside.
FROM CONTROL VALVE
FROM CONTROL VALVE
REVERSE NOTCH
SPOOL
FROM
REMOTE CONTROL
VALVE
FROM
SOLENOID
VALVE
CUSHION SPOOL
ARM IN, STOPPED
CUSHION SPOOL
As the cushion spools are forcedly pushed down, when the arm is OUT, both in operation and not in operation, the pilot
pressure goes through the inside of the cushion valve without passing the throttle.
The heat oil from Port R returns to the hydraulic oil tank via Port T when the lever is in neutral. While the lever is being
moved, the oil flows to the remote control valve.
Lep SM4608016-0EN
Issued 09-07
Copyright
8016-9
Disassembly
STEP 4

steps refer to the schematic on page 3.
STEP 1
10
13
JD00552A
Remove the spool (13) and the spring (10) from the
control valve.
STEP 5
JD00549A
If the cushion control valve has to be replaced, remove

the adaptors and elbow unions and install them on the
new control valve. Do not remove the four flow restriction adapters (7) installed in the sides of the valve.
NOTE: Mark parts to ensure correct assembly in same
valve bore as removed from.
11
13
STEP 2
10
9
JD00553A
NOTE: Removal to be carried out in case of a leak

between the spool (13) and the spring guide (11).
Put the spool (13) in a vice using wooden shims to protect the spool. Remove the spring guide (11) from the
spool (13).
JD00550A
Remove the plug (8) with the O-ring (9) and the spring
(10).
STEP 3
10
8
JD00551A
Remove the spring (10) and the O-ring (9) from the
plug (8). Scrap the O-ring.
Lep SM4608016-0EN
Issued 09-07
Copyright
8016-10
STEP 6
STEP 10
11
12
4
JD00554A
Remove the O-ring (12) from the spring guide (11).

Scrap the O-ring.
JD00557A
STEP 11
STEP 7
Repeat steps 2 through 6 for the other spool.
STEP 8
5
A
6
2
7
JD00555A
Remove the flow restriction adaptor (7) and the O-ring

(6).
JD00558A
Install an M4 cap screw (A) in the tapped hole of the

spool (3). Remove the spool (3) with the spacer (5) and
the spring (2). Remove the M4 cap screw.
STEP 12
3
STEP 9
5
7
JD00559A
Remove the spring (2) and the spacer (5) from the
spool (3).
JD00556A
Remove and discard the O-ring (6) and the flow restriction adaptor (7).
Lep SM4608016-0EN
STEP 13
Repeat steps 9 through 12 for the remaining three
spools.
Issued 09-07
Copyright
8016-11
Inspection
Assembly
STEP 1

Clean all parts using suitable cleaning solvent.

Immerse valve housing in cleaning solvent for several
minutes to dissolve dirt or other foreign matter inside
valve housing. Use low pressure compressed air to
blow out any foreign matter from interior of valve housing. Dry parts using clean cloths.
NOTE: Lubricate all parts with clean hydraulic oil.

Ensure that parts are assembled in the same groove as
they were removed from.
STEP 1
STEP 2
Inspect springs for cracks, distortion, or evidence of

permanent set. Replace a spring if any of these defects
are observed.
STEP 3
Check the spools for cracks, holes, distortion or other
damage. Check that the spools slide easily in the
groove of the control valve housing. If any defects are
observed replace the cushion valve.
STEP 4
JD00559A
Check the plugs, flow restriction adapters, and spring

guides for damaged threads. Check the ports in flow
restriction adapters for foreign matter, chipping, or other
damage. Check spring guides for bent condition.
Replace a defective part.
Install the spacer (5) on the spool (3).
STEP 2
STEP 5
Check the spacer for chipping, wear and signs of damage. If any of these conditions are seen replace the
spacer.
STEP 6
Check for damaged threads and signs of internal wear
on the control valve housing. If any defects are seen,
replace the cushion valve.
3
5
JD00560A
Install the spring (2), the spool (3) and the spacer (5) in
the control valve housing.
Lep SM4608016-0EN
Issued 09-07
Copyright
8016-12
STEP 3
STEP 7
11
3
4
13
JD00561A
Install the spring (4) in the spool (3).
JD00563A
Place the spool (13) in a vice using wooden shims to

protect it and tighten the spring guide (11).
STEP 4
STEP 8
10
11
6
13
7
JD00562A
Install a new O-ring (6) on the flow restriction adaptor

(7). Install the flow restriction adaptor in the control
valve housing.
Install the spring (10), the spring guide (11) and the
spool (13) in the groove of the control valve housing.
STEP 5
STEP 9
JD00564A
Repeat steps 1 through 4 for remaining three spools.
10
STEP 6
11
12
13
JD00565A
Install the spring (10).

JD00554A
Install the spring guide (11) using a new O-ring (12) on

the spool (13).
Lep SM4608016-0EN
Issued 09-07
Copyright
8016-13
STEP 10
9
8
JD00566A
Install a new O-ring (9) on the plug (8). Install the plug
and O-ring in the housing.
STEP 11
Repeat steps 6 through 10 for the other spool.
STEP 12
JD00549A
If removed, install the adapters and elbows on the control valve.
Lep SM4608016-0EN
Issued 09-07
Copyright
8016-14
NOTES
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Lep SM4608016-0EN
Issued 09-07
Copyright
Section
8017
8017
SAFETY VALVES
CNH
Lep SM4608017-0EN

Printed in France
September 2007
Copyright
8017-2
TABLE OF CONTENTS
BOOM SAFETY VALVE ................................................................................................................................................. 3
Identifying the ports .................................................................................................................................................... 3
Removal ..................................................................................................................................................................... 3
Installation .................................................................................................................................................................. 3
Disassembly ............................................................................................................................................................... 4
Assembly ................................................................................................................................................................... 6
DIPPER RELIEF VALVE ................................................................................................................................................ 8
Identifying the ports .................................................................................................................................................... 8
Removal ..................................................................................................................................................................... 8
Installation .................................................................................................................................................................. 8
Disassembly ............................................................................................................................................................... 9
Assembly ................................................................................................................................................................. 11
Lep SM4608017-0EN
Issued 09-07
Copyright
8017-3
BOOM SAFETY VALVE

Installation

2
3
When installing, use the same procedure in the reverse

order of removal by assembling new seal rings.
For valve adjustment, see Section 8001.
6
CD02C001
1
2
3
4
5
6
PILOT SPOOL
LEAK RETURN
HIGH PRESSURE CIRCUIT BYPASS TOWARDS THE OTHER
VALVE
VALVE POWER SUPPLY
SCREW
SAFETY VALVE
Removal
NOTE: Before performing any operation on the
machine, carry out the following operations in the order
shown.
- Lower the attachment to the ground.
- Shut down the engine.
- Release pressure in the hydraulic circuit (see Section
8000).
Remove the hoses (1), (2) and (3) and plug the unions
and the hoses.
Remove the tube (4) and plug the ports.
Remove the screws (5) and the relief valve (6).
Plug the cylinder port.
Lep SM4608017-0EN
Issued 09-07
Copyright
8017-4
Disassembly
13
16
12
17
14
18
19
15
11
6
7
1
2
10 9
Remove the spool stop cap (1) and discard the seal (2).
Remove the screws (3), then the cover (4), discard the
seal (5) and remove the springs (6) and (7).
Remove the washer (8) and the spring seat (9).
Remove the spool (10).
Lep SM4608017-0EN
4
CS02J542
Remove the plug (12), discard the seal (16), remove

the spring (14) and the check valve (15) and mark their
positions.
Remove the plug (16), discard the seal (17), remove
the spring (18) and the check valve (19) by marking
their positions.
Remove the valve (11).
Issued 09-07
Copyright
8017-5
17
12
11
16
2
1
15
14
13
3
10
CS02J543
Remove the plug (1), the setting screw (2) and discard
the seal (3).
Remove the spring (4) and the check valve (5).
Remove the body (6) and discard the seal (7).
Remove the spring seat (8), discard the seal (9) and the
back up ring (10).
Extract the check valve (12) from the sleeve (15),
discard the seal (13) and the back up ring (14).
Discard the seal (16) and the back up ring (17) from the
sleeve (15).
Lep SM4608017-0EN
Issued 09-07
Copyright
8017-6
Assembly
17
7
4
2
16
12 11
1
15
14
3
13
10
CS02J543
NOTE: When assembling, install new seal rings.

Install a seal (16) and a back up ring (17) on the sleeve
(15).
Install a seal (13) and a back up ring (14) on the check
valve (12).
Lubricate and install the check valve (12) in the sleeve
(15).
Install a seal (9) and a back up ring (10) on the spring
seat (8).
Install the spring seat (8) taking care not to damage the
seal (9) and the back up ring (10).
Lep SM4608017-0EN
Install a seal (7) on the body (6).

Lubricate the body (6) and the inside of the spring seat
(8).
Put the body (6) in place.
Install a seal (3) on the screw (2).
Install the screw (2) without tightening it too much, the
final tightening will be done with pressure setting.
Install the blank nut (1).
Issued 09-07
Copyright
8017-7
13
12
16
17
18
19
14
15
11
6
7
2
4
10
3
8
5
CS02J542
Install an O-ring (2) on the spool stop cap (1).

Install the cap (1) on the relief valve.
Lubricate and install the spool (10).
Install the washer (8) and the spring seat (9).
Install the springs (6) and (7) in the cover (4).
Install an O-ring (5) on the cover (4).
Install the cover (4) using screws (3).
Install the valve (11).
Lep SM4608017-0EN
NOTE: Take care in respecting the position of each

check valve assembly marked during disassembly.
Install an O-ring (17) on the plug (16).
Lubricate and install the check valve (19) and the
spring (18).
Install and tighten the plug (16).
Install an O-ring (13) on the plug (12).
spring (14).
Install and tighten the plug (12).
Issued 09-07
Copyright
8017-8
DIPPER RELIEF VALVE

Installation
When installing, use the same procedure in the reverse
order of removal, by assembling new seal rings.
For valve adjustment, see Section 8001.
3
1
4
5
6
1
2
3
4
5
6
PILOT SPOOL
VALVE POWER SUPPLY
SPOOL LEAK RETURN
VALVE LEAK RETURN
SCREW
RELIEF VALVE
Removal
NOTE: Before performing any operation on the
machine, carry out the following operations in the order
shown.
- Lower the attachment to the ground.
- Shut down the engine.
- Depressurise the hydraulic circuit (see Section 8000).
Remove the hoses (1), (3) and (4) and plug the unions
and the hoses.
Remove the tube (2), plug the tube and the union.
Remove the screws (5) and the relief valve (6).
Plug the cylinder port.
Lep SM4608017-0EN
Issued 09-07
Copyright
8017-9
Disassembly
1
2
9
21
10
5
16
17
11
14
12
20
19 18 15
13
CS02J541
Remove the screws (1) and the cover (2), discard the
seal (3).
Remove the spring (4) and the check valve (5) after
marking their positions.
Remove the screws (6) and the cover (7), discard the
seal (8).
Remove the spring (9) and the check valve (10) after
marking their positions.
Remove the retaining screws from the spool stop cap
(11), remove it and discard the seal (12).
Remove the screws (13) and remove the cover (14),
discard the seal (15).
Remove the springs (16) and (17).
Remove the seats from the spring (18) and (19).
Remove the spool (20).
Remove the valve (21).
Lep SM4608017-0EN
Issued 09-07
Copyright
8017-10
16
17
12
11
4
2
1
13
15
3
14
10
CS02J543
Remove the plug (1), the setting screw (2) and discard
the seal (3).
Remove the spring (4) and the check valve (5).
Remove the body (6) and discard the seal (7).
Remove the spring seat (8), discard the seal (9) and the
back up ring (10).
Extract the check valve (12) from the sleeve (13),
discard the seal (14) and the back up ring (15).
Discard the seal (16) and the back up ring (17) from the
sleeve (13).
Lep SM4608017-0EN
Issued 09-07
Copyright
8017-11
Assembly
17
11
12
4
2
16
13
15
14
10
CS02J543
NOTE: When assembling, install new seal rings.

Install a seal (16) and a back up ring (17) on the sleeve
(13).
Install a seal (14) and a back up ring (15) on the check
valve (12).
Lubricate and install the check valve (12) in the sleeve
(13).
Install a seal (9) and a back up ring (10) on the spring
seat (8).
Install the spring seat (8) taking care not to damage the
seal (9) or the back up ring (10).
Lubricate the body (6) and the inside of the spring seat
(8).
Put the body (6) in place.
Install a seal (3) on the screw (2).
Install the screw (2) without tightening it too much, the
final tightening will be done with pressure setting.
Install a seal (7) on the body (6).
Lep SM4608017-0EN
Issued 09-07
Copyright
8017-12
7
10
4
21
16
17
11
14
12
20 19 18 15
13
CS02J541
Install the valve (21).

Lubricate and install the check valve (5) and the spring
(4) according to the marks made during disassembly,
install the cover (2) equipped with a seal (3). Install the
screws (1).
spring (9) according to the marks made during
disassembly, install the cover (7) equipped with a seal
(8). Install the screws (6).
Install a seal (12) on the spool stop cap (11). Install the
retaining screws.
Lubricate and install the spool (20).
Install the spring seats (18) and (19).
Install the springs (16) and (17).
Install a seal (15) on the cover (14).
Install and fasten the cover (14) using screws (13).
Lep SM4608017-0EN
Issued 09-07
Copyright
Section
8018
DISASSEMBLY AND REASSEMBLY
8018
OF THE HYDRAULIC SWIVEL
CNH
Lep SM4608018-0EN

Printed in France
September 2007
Copyright
8018-2
TABLE OF CONTENTS
SPECIAL TORQUE .........................................................................................................................................................2
SPECIAL TOOLS ............................................................................................................................................................3
HYDRAULIC SWIVEL .....................................................................................................................................................4
Description ..................................................................................................................................................................4
Disassembly ...............................................................................................................................................................5
Assembly ....................................................................................................................................................................7
SPECIAL TORQUE
Cover retaining screws (7) ....................................................................................62.7 to 72.5 Nm (46.24 to 53.47 lbf-ft)
Thrust plate retaining screws (9)...........................................................................31.4 to 37.3 Nm (23.16 to 27.51 lbf-ft)
Lep SM4608018-0EN
Issued 09-07
Copyright
8018-3
SPECIAL TOOLS
Jig for pushing out axle
M16-M20 FULLY THREADED BOLT
F
SCREW
M16-M20 FEMALE
G
B
A
D
COVER (6)
FITTING SIZE
Lep SM4608018-0EN
30 - 40 mm (1.18 - 1.57 in)
20 mm (0.79 in)
20 mm (0.79 in)
350 - 400 mm (13.78 - 15.75 in)
20 mm (0.79 in)
7 x 25 mm (0.27 x 0.98 in)
5 mm (0.197 in)
Issued 09-07
Copyright
8018-4
HYDRAULIC SWIVEL
Description
1
2
3
4
5
6
PIVOT
"V" SEAL
O-RING
PAKING RING
ROTOR
COVER
7
8
9
10
11
SCREW *
LOCTITE
SCREW *
THRUST PLATE
O-RING
NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).
Lep SM4608018-0EN
Issued 09-07
Copyright
8018-5
NOTE: For removing the hydraulic swivel, refer to Section 8006.
STEP 3
Disassembly
Always handle the components carefully. Never force,
hit or drop components. Avoid any contamination by
dust, water or foreign bodies. Work in a clean area with
clean tools. Always remove the pivot (inner component)
and the bushing (outer component) using a press.
STEP 1
Remove the screws (9) and the thrust plate (10).
STEP 4
Remove the screws (7) and the cover (6).
STEP 2
Push out the axle (1) from the rotor (5) using a jig.
STEP 5
Remove and discard the O-ring (11).
Remove the "V" seal (2) from the pivot (inner component) (1) and discard it.
Lep SM4608018-0EN
Issued 09-07
Copyright
8018-6
STEP 6
Remove the O-ring (3) and the sealing rings (4) from
inside the bushing (outer component) (5). Discard the
sealing rings and the O-ring.
Lep SM4608018-0EN
Issued 09-07
Copyright
8018-7
Assembly
STEP 3
Clean all the components. Polish any scratches or

rough areas with an oil stone. Use seals, O-rings and
new sealing rings. Take the same precautions as during
removal.
STEP 1
Check the proper installation of the O-ring and the sealing rings using a mirror. Apply hydraulic fluid, make
sure that the components are not protruding, twisted,
etc.
Clean the bushing (outer component) with a cleaning
solvent or low pressure compressed air.
STEP 2
Set one packing rings (4) in each groove up to the second from the top.
Set the O-ring (3) in the top groove.
Lep SM4608018-0EN
Issued 09-07
Copyright
8018-8
STEP 4
STEP 7
Install a new "V" seal (2) on the pivot (inner component)

(1) and coat it with clean hydraulic oil.
Install the O-ring (11).
STEP 8
STEP 5
Insert the pivot (inner component) (1) in the bushing

(outer component) (5).
Install the cover (6) and the screws (7). Tighten the
screws to torque (see page 2).
NOTE: Do not cut through the "V" seal, or graze it.
STEP 6
Install the thrust plate (10) and the screws (9).
Lep SM4608018-0EN
Issued 09-07
Copyright
Section
8019
8019
DISASSEMBLY AND REASSEMBLY

OF THE SWING HYDRAULIC MOTOR
CNH
Lep SM4608019-0EN

Printed in France
September 2007
Copyright
8019-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 3
TORQUE SETTINGS ...................................................................................................................................................... 3
SPECIAL TOOLS ............................................................................................................................................................ 3
HYDRAULIC SWING MOTOR ........................................................................................................................................ 4
Description .................................................................................................................................................................. 4
Disassembly................................................................................................................................................................ 6
Inspection.................................................................................................................................................................... 9
Maintenance Reference Table .................................................................................................................................. 10
Assembly .................................................................................................................................................................. 11
SECONDARY RELIEF .................................................................................................................................................. 20
Description ................................................................................................................................................................ 20
Disassembly.............................................................................................................................................................. 21
Inspection.................................................................................................................................................................. 21
Assembly .................................................................................................................................................................. 21
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-3
SPECIFICATIONS
See Section 1002.
TORQUE SETTINGS
Bypass valve plug (27)........................................................................................................................ 78 Nm (57.53 lbf-ft)
Non return check valve plug (52) .................................................................................................... 137 Nm (101.04 lbf-ft)
Cover screw (49) and (56) .............................................................................................................. 157 Nm (115.79 lbf-ft)
Safety valve (48) ............................................................................................................................. 137 Nm (101.04 lbf-ft)
SPECIAL TOOLS
C
D
Press fitting jig for inner ring (2) and taper roller
bearing (4)
A 60 mm
C 130 mm
B 55.2 0.1 mm
D 140 mm
E 15
Installation jig for brake piston (12)

A 190 mm
C 50 mm
B 220 mm
C
G
H
D
E
A
B
C
D
Installation jig for oil seal (3)

100 mm
E 20 mm
81 mm
F 155 mm
60 02 mm
G 30
50 - 01 mm
H 3 mm
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-4
HYDRAULIC SWING MOTOR

Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
A
B
SLEEVE
SNAP RING
OIL SEAL
BEARING
RETAINING WASHER
PISTON FACE
THRUST PLATE
PISTON ASSEMBLY
FRICTION DISK
STEEL DISK
O-RING
BRAKE PISTON
O-RING
SPRING
COVER
O-RING
PLUG
PISTON
SPRING WASHER
TEFLON SEAL
BUSHING
DISTRIBUTION PLATE
BEARING
CYLINDER
HOUSING
SPRING
BYPASS VALVE PLUG
CHECK VALVE
SPRING
O-RING
BACKUP RING
NON-RETURN CHECK VALVE
SPRING SEAT
CHECK VALVE SEAT
CHECK VALVE
SPRING
O-RING
SHIM
VALVE HOUSING
PISTON
O-RING
O-RING
BACKUP RING
PLUG
SLEEVE
LINER
NUT
SECONDARY RELIEF ASSEMBLY
SCREW
BACKUP RING
O-RING
NON-RETURN CHECK VALVE PLUG
SNAP RING
RETAINING PIN
RETAINING PIN
SCREW
SHOE
BRAKE PILOT PORT
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-5
37
49
31 33
30
32
31
30
48
47
29
41
28
46
27
45
44
42 43
40 39 38 36 35 34 26
19
21 20
52
15
51
18
17
50
16
54
14
55
13
22
12
11
23
10
9
53
24
25
A
6
1
CS02J563
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-6
Disassembly
STEP 1
STEP 3
48
56
48
49
52
15
26
33
27
Remove the oil level dipstick (C) and dipstick tube (D).
Remove relief valve assemblies (48) from swing motor.
Remove the by-pass valve assemblies (27), as well as
the plugs (52), the springs (26) and the non-return
check valves (33).
Remove and discard all the O-rings of each component.
STEP 2
Remove the retaining screws (49) and (56). Remove

the cover (15) from the motor housing.
STEP 4
53
23
22
18
15
CS02C520
Place the cover with the shaft on top and remove the
retaining ring (53) from the shaft.
Remove the needle bearing (23) and the distribution
plate (22).
Remove the pistons (18) from the distribution plate
(22).
To facilitate assembly, put alignment marks (A) on the

cover and motor housing.
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-7
STEP 5
STEP 8
NOTE: Protect the housing and the piston surfaces with
rags when you lever the piston out of the housing.
13
13
12
15
A
A
12
CS02C521
13
Remove and discard the large O-ring (13) from the

cover (15).
25
STEP 6
21
20
19
Install two M6 screws (A) in tapped holes of the brake

piston (12). Lever these screws and free the brake piston (12) from the housing.
Remove and discard the O-ring (13) from the housing
(25) and the brake piston (12). Remove the two M16
screws (A) from the brake piston.
15
CS02C522
Remove the bushings (21), the Teflon rings (20) and

the washers (19) from the cover (15).
STEP 9
10
STEP 7
14
25
9
25
Remove the springs (14) from the brake piston (12).

Remove the four friction plates (9) and the four disc
plates (10) from the swing motor housing (25).
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-8
STEP 10
STEP 12
24
1
4
25
CS02C528
Remove the retaining ring (2) from the fluted shaft.

Remove the conical roller bearings and the sleeve (1)
using an antisticking pin puller.
Remove the cylinder assembly (24) from the motor
housing (25).
STEP 11
STEP 13
NOTE: Mark the location of the pistons on the base
plate and on the cylinder. Pistons must be installed in
same positions during assembly.
4
3
6
7
24
Remove the bearing (4) from the motor housing.

Position the motor housing in a press. Using a suitable
sleeve or a centring piece, drive the spy joint (3) out
from the housing. Scrap the spy joint (3).
Remove the piston plate (6), the piston assembly (8)
and the base plate (7) from the cylinder (24).
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-9
Inspection
STEP 14
STEP 1
Check the distribution plate sliding surfaces for signs of

seizing or wear. If there is evidence of seizing or wear,
the plate should be replaced.
STEP 2
Check for wear of the pistons. Replace the motor if the
depth of any shoe sliding surface is less than 0.45 mm,
if the shoe surfaces are seriously damaged or if a piston assembly shows any sign of seizing. There should
be no wear of the external surfaces of the piston
assemblies.
CS02C530
Slip the piston plate (6) out of the sliding surfaces of the
piston assemblies (8), while ensuring that it does not
get damaged. Remove the pistons from the base plate
(7).
STEP 15
STEP 3
Check for signs of seizing or wear on the piston plate
sliding surface. The plate should be replaced if there is
evidence of seizing or wear.
STEP 4
Check for signs of seizing, wear or damage on the cylinder piston bores. The motor should be replaced if
there is evidence of seizing or if the piston bores are
damaged.
Inspect the needle bearing and tapered roller bearing

for damage. The bearings should be replaced if any
damage is found, or after 3000 hours of operation.
24
CS02C531
Remove the backup washer (5) from the fluted shaft.
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-10
Maintenance Reference Table

Table 1
Part name
Locations to be inspected and measured
Reference valves
(tolerance limits)
Measuring instruments
Instructions for repair

and remedies
Piston assembly (8)
Roughness on
shoe sliding face
0.8 S
Surface roughness
gauge
Repair with paper

lap.
Groove depth in
0.45 mm or more
shoe sliding section
Micrometer
Replace with new

ones.
Looseness on the
ball joint section be0.4 mm or less
tween piston and
shoe
Dial gauge
Replace with new

ones.
Piston face (7)

Cylinder (24)
Distribution plate (22)

Piston assembly (8)
Cylinder (24)
Piston diameter
Almost no wear. If scratches or seizure are found, replace with new

ones.
Surface roughness
0.8 S
Surface roughness
gauge
Lap
Roughness on the
edge
0.4 S
Surface roughness
gauge
Lap
Piston hole
Almost no wear. If scratches or seizure are found, replace the motor.
Surface roughness
0.8 S
Clearance between
piston diameter and 0.04 mm or less
cylinder bore
Surface roughness
gauge
Lap
Micrometer
Air micrometer
Motor replacement
Table 2
Part name
Inspection and Maintenance Reference
Taper roller bearing (4)

Needle bearing (23)
Replace bearings with new ones every 3,000 hours even if they function normally.
Additionally, always replace bearings when reassembling, even if it's within 3,000
hours.
Spy joint (3)
If damage is found on the lip, replace it with a new one.

Additionally, replace seals with new ones every 3,000 hours even if they function
normally with no leaking.
Additionally, always replace seals when reassembling, even if it's within 3,000
hours.
O-rings (11), (13), (16), (30), If damage is found on O-ring, replace it with a new one.
Additionally, replace rings with new ones every 3,000 hours even if they function
(37), (41), (42) and (51)
normally with no leaking.
Additionally, always replace rings when reassembling, even if it's within 3,000
hours.
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-11
Assembly
STEP 1
STEP 3
7
SPHERICAL
24
24
CS02C532
Apply grease (No. 2 EP lithium grease) on the spherical

portion of the cylinder shaft that is in contact with the
retaining washer (5) and install the retaining washer
(5).
STEP 2
CS02C534
Apply clean hydraulic fluid on the cylinder (24) bores.

Install the piston assemblies (8) and the thrust plate (7)
in the barrel (24). Be sure that the pistons are installed
in the same bores as they were removed from.
STEP 4
8
6
7
A
CS02C533
24
Apply clean hydraulic fluid on the sliding surface of the

piston assemblies (8). Install the piston assemblies (8)
in the ports of the base plate (7).
CS02C535
Apply clean hydraulic fluid on the sliding surfaces of the

piston assemblies (A) and install the piston plate (6).
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-12
STEP 5
STEP 7
PRESS-FITTING JIG
A
4
(INNER)
24
CS02C536
Install a new taper roller bearing inner cage (4) on the

barrel shaft (9).
STEP 6
PRESS-FITTING JIG
Before installation, apply grease on the lip of the oil seal

(3). Position housing in a press. Apply Loctite 504 to the
periphery of the lip seal. Install and centre the oil seal
(3) in the bore of the housing. With a suitable sleeve
(A), fit the oil seal (3) in the bore of the housing.
NOTE: Pay attention to the fitting directions of the oil
seal (3).
2
LOCTITE APPLIED
TAPER ROLLER BEARING SIDE
4
CYLINDER OUTPUT SHAFT SIDE
24
STEP 8
4
(OUTER RING)
CS02C537
Apply a thin coat of Loctite 515 or 518 where the sleeve

(1) is installed on the cylinder shaft. Fit the sleeve (1) on
the shaft and install the snap ring (2).
25
Install a new bearing outer cage (4) in the housing (25).
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-13
STEP 9
STEP 11
CYLINDER END FACE
13
24
12
11
HOUSING END FACE
25
25
Apply grease on the new O-rings (11) and (13); install
the O-ring (11) in the housing (25) and the O-ring (13)
on the brake piston (12).
STEP 12
A
(B) 40 to 50 mm (1.57 in to 1.96 in)

Install the housing (25) on shims (A).
Carefully install the barrel assembly (24) in the housing
(25). Be careful when installing the cylinder assembly
not to damage the splines on the shaft.
STEP 10
REINFORCING JIG
12
25
10
Apply clean hydraulic fluid on the periphery of the brake

piston (12). Push the brake piston (12) into the housing
(25).
25
Apply clean hydraulic fluid to both faces of the friction

disks (9) and the steel disks (10). First, install a steel
disk then a friction disk, then a steel disk, a friction disk,
then a steel disk, a friction disk, finally the last steel disk
and the last friction disk.
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-14
STEP 13
PORTS A AND B SIDE
V SHAPED GROOVE
14
25
ROUND SHAPED GROOVE

RELIEF SIDE
STEP 15
53
Install the springs (14) in the brake piston (12) in their
original locations.
23
STEP 14
22
18
21
15
20
19
54
J7CB20C-26
Install the new needle bearing inner race (23) on the

shaft and install the retaining ring (53).
STEP 16
13
15
J7CB20C-28
Install the spring washers (19) in the cover (15). Apply

No. 2 EP lithium grease on the bushings (21), the new
Teflon rings (20) and in the cover (15). Install a Teflon
ring on each of the bushings. Install the bushings with
seals in their holes in the cover.
Apply No. 2 EP lithium grease on the pistons and install
the pistons (18) in the distribution plate (22). Be sure
that the pistons are installed in same bore as they were
removed from. Install the pistons and the distribution
plate (22) on the cover (15), positioning the plate hole
on the stop dowel (54).
15
J7CB20C-30
Install a new, greased O-ring (13) on the cover (15).
NOTE: Pay attention to the installation directions for the

distribution plate (22) on the cover (24), which were
marked before disassembly.
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-15
STEP 17
STEP 19
56
25
49
15
25
LOCTITE 504
Apply Loctite 504 to the mating surfaces of the motor

housing (25) and the cover (15).
STEP 18
Install the retaining screws (49), (56) and tighten to a

torque of 157 Nm.
STEP 20
48
15
48
52
55
26
26
25
33
27
D
Carefully install the cover (15) and the distribution plate
(22) on the housing, making sure that the distribution
plate and bushings do not fall off the cover. Align the
motor and cover marks, engage the stop dowel (55) in
the brake piston orifice (12).
Lep SM4608019-0EN
Install the oil level dipstick (C) and dipstick tube (D).
Install the relief valve assemblies (48) on the swing
motor.
Install the by-pass valve assemblies (27) and the plugs
(52), the springs (26) and the non-return check valves
(33).
Install new O-rings on each component.
Issued 09-07
Copyright
8019-16
STEP 21
PORT P
15
25
Open the entry and exit ports and apply pilot pressure
of 2.9 to 4.9 MPa to the brake relief port.
Then make sure that the output shaft can be smoothly
rotated, one turn or more, with torque of 30 to 40 Nm
If it does not rotate properly, it is suspected that assembly is not completed correctly.
Disassemble once again and readjust it.
Make sure that drain port is released.
NOTE: Ensure that the set pressure on the relief valve
(48) indicates a normal pressure after the hydraulic
motor is installed onto this machine.
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-17
TROUBLESHOOTING
Described below are measures to be taken when any abnormalities or malfunctions are found while the hydraulic motor
is used.
Details on disassembling/inspection and reassembling are also described later but careful handling is absolutely
needed to avoid any damage to the sliding parts of the motor while conducting these procedures.
Table 1
Symptom
Cause
Exterior inspection
Does not Motor's

internal Measure drain output.
rotate
breakage
Motor's
internal Open the inlet and outlet
breakage
ports on the motor and apply
pilot pressure of 2.9 to 4.9
MPa to the brake relief port.
Then attempt to rotate the
output shaft with torque of 30
to 40 Nm.
Remedy
Repairs
If motor supply input is equal See Table 2.

to the drain output, there is
high possibility of breakage
in sliding section. Disassembling/inspection is required.
If the output shaft does not Replace
damrotate smoothly with the aged parts or
torque stated to the left, motor assembly.
there is high possibility of
internal breakage. Disassembling/inspection
is
required.
Incorrect settings Measure load pressure with Reset to specified set presat relief valve in pressure gauge.
sure.
the circuit
Excessive
slippage
Wear or damage Measure drain output.

in the sliding part
of the motor and in
the high pressure
seal section
If the drain output is more See Table 2.

than 2.5 L / min., the leakage
is too high. Disassembling/
inspection is required.
Oil temperature is Measure oil temperature.

too high and there
is excessive internal leakage inside
the motor
Lower the oil temperature.
Lack
torque
of Wear or seizure of
the motor sliding
section
Abnormal
noises
Open the inlet and outlet

ports on the motor and apply
pilot pressure of 2.9 to 4.9
MPa to the brake relief port.
Then attempt to rotate the
output shaft with a torque of
approx. 30 to 40 Nm.
If the output shaft does not

rotate smoothly with the
torque stated to the left,
there is high possibility of
is
required.
Inspect parts (a) to

(e) listed in Table
2, and also the
bearings. Change
them if any abnormality is found.
Incorrect settings Measure load pressure with Reset to specified set presat relief valve in pressure gauge.
sure.
the circuit
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-18
Symptom
Cause
Exterior inspection
Lack
torque
of Motor's
internal Check whether there are any
breakage
foreign metal substances in
the motor oil drain and drain
Abnormal
filters.
noises
(cont.)
Remedy
Repairs
If any foreign metal substances are found, there is

high possibility of motor's
is
required.
Repair or replace
damaged parts.
Motor
assembly
replacement.
A lot of air is Check the oil in the tank and Bleed air completely.
mixed in the oil
motor case.
Looseness
on Looseness on piping fix- Fasten them with proper
tightening sections tures.
tightening torque.
Check for looseness on the
fixture mounting bolts, motor
mounting bolts and bolts on
the motor.
Abnormal
heat
Seizure of motor's Check for foreign metal subsliding and rotat- stances in the motor oil drain
and drain filters. Apply pilot
ing sections
pressure of 2.9 to 4.9 MPa to
the brake relief port and
attempt to rotate the output
shaft with torque of 30 to 40
Nm.
If any foreign metal substances are found or the output shaft does not rotate
smoothly with the torque
above, there is a high possibility of internal breakage.
Disassembling/inspection is
required.
Oil leak- O-ring is damage from aged.

mating
Oil seal surface is
faces
damaged.
Loose bolts
Oil leak- Wear or damage
age from on the lips of oil
seal
oil seal.
Wear or damage
on seal sections of
shaft
Repair or replace
damaged parts.
Motor
assembly
replacement.
Replace O-rings.
Repair or replace
seal surfaces.
Check for loose bolts.
Fasten them with proper

tightening torque.
Replace oil seal.
Repair or replace
motor assembly.
Abnormal
pres- Check the internal pressure Internal pressure in the case Replace oil seal.
and drain output in the case. should be 0.3 MPa or less.
sure in the case
Repair or replace
If drain output is too large, damaged parts.
disassembly/inspection
is
Motor
assembly
required.
replacement.
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-19
Table 2
Letter
Parts to be inspected
Repairs
Wear in the sliding part of the distribution plate (22)
Repair or replace parts.
Damage in the sliding section of the piston plate (6)
Repair parts or replace the motor.
Damage in the sliding section of the piston assembly (8)
Wear in piston outer diameter of the piston assembly (8)
Wear in piston hole of the cylinder (24)
Replace motor.
Damage in Teflon ring (20)
Replace parts.
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-20
SECONDARY RELIEF
Description
38
41
47
40
44
34
35
36
37
39
45
46
43
42
CS02C552
34
35
36
37
38
39
40
SPRING SEAT
CHECK VALVE
SPRING
O-RING
SHIM
VALVE BODY
PISTON
Lep SM4608019-0EN
41
42
43
44
45
46
47
O-RING
BACK-UP RING
O-RING
PLUG
SLEEVE
LINER
NUT
Issued 09-07
Copyright
8019-21
Disassembly
Inspection
STEP 1
NOTE: Individual relief valve assembly parts cannot

be replaced. If a relief valve assembly fails to operate
properly for any reason other than dirt or foreign matter, the entire assembly must be replaced.
Remove the nut (47), the plug (44), discard the

seal (43) and the back up ring (42).
STEP 2
Remove the sleeve (45) and the piston (40).
STEP 3
Remove the liner (46), the shim (38) and discard the
O-ring (41).
STEP 4
Assembly
NOTE: When installing, install new seal rings.
STEP 1
Install an O-ring (37) on the valve body (39).
Remove the spring (36), the check valve (35) and the
spring seat (34).
STEP 2
STEP 5
Install the spring seat (34) in the valve body (39).
Remove and discard the O-ring from the valve

body (39).
STEP 3
Oil the inside of the spring seat (34). Install the check
valve (35) in the spring seat (34).
STEP 4
Install the spring (36) on the valve body (39).
STEP 5
Install an O-ring (41) on the liner (46). Install a shim
(38) on the spring (36).
STEP 6
Install the liner (46) in the valve body (39), taking care
not to damage the O-ring (41).
STEP 7
Install the piston (40) in the sleeve (45). Install the
sleeve (45) in the liner (46).
STEP 8
Install a back up ring (42) and an O-ring (43) on the
plug (44). Install the plug (44) in the liner (46).
STEP 9
Lep SM4608019-0EN
Issued 09-07
Copyright
8019-22
NOTES
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Lep SM4608019-0EN
Issued 09-07
Copyright
Section
8020
CNH
Lep SC4608020-0EN

Printed in France
March 2007
8020
HYDRAULIC FUNCTIONS
Copyright
8020-2
TABLE OF CONTENTS
HYDRAULIC FUNCTIONS...................................................................................................................................... 3
List of functions ................................................................................................................................................... 3
TRAVEL CIRCUITS ................................................................................................................................................ 6
1. High-speed Travel Circuit................................................................................................................................ 6
2. Low Speed Travel Circuit ................................................................................................................................ 8
3. Straight Travel Circuit.................................................................................................................................... 10
SWING CIRCUITS ................................................................................................................................................ 12
1. Swing Parking Circuit (Lever in Neutral / Swing Locked).............................................................................. 12
2. Swing Parking Circuit (Brake Released) ....................................................................................................... 14
3. Swing Push Digging ...................................................................................................................................... 16
ARM CIRCUITS .................................................................................................................................................... 18
1. Arm Out Circuit ............................................................................................................................................. 18
2. Arm-In Load Holding ..................................................................................................................................... 20
3. Arm-In Circuit ................................................................................................................................................ 22
BOOM CIRCUITS ................................................................................................................................................. 24
1. Boom-Up Circuit (Single) .............................................................................................................................. 24
2. Boom-Up Circuit (Combined) ........................................................................................................................ 26
3. Boom-Down Load Holding ............................................................................................................................ 28
4. Boom-Down Circuit ....................................................................................................................................... 30
BACKUP CIRCUITS.............................................................................................................................................. 32
1. Combined Circuit (Breaker Circuit) ............................................................................................................... 32
2. Combined Circuit (High Speed Confluence Circuit) ...................................................................................... 34
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-3
HYDRAULIC FUNCTIONS
List of functions
Functions
Description
Pages
Travel Circuits
1) High speeds can be achieved by setting the two-level inclinatory angle of the
travel motor to the smaller angle side.
High speed travel
2) Load pressure applied to the travel motor automatically changes the speed to
circuit
the lower speed.
3) Travel load pressure does not regulate the controller.
Page 6
Low speed travel

circuit
Low speeds can be achieved by setting the two-level inclinatory angle of the travel
motor to the larger angle side.
Page 8
Maintains machine's straight travel when attachment or swing operations are

performed during its travel.
Page 10
Straight travel
circuit
Swing Circuits
1) When the swing lever is in neutral, the swing parking is activated and the swing
is fully held.
2) When the swing lever is operated, the parking brake is released by signals from
the pressure switch.
3) When the swing lever is in neutral, the parking brake is released by load
pressure generated by attachment operation.
4) The parking brake starts to operate 5 seconds after the swing lever comes in
neutral and after the load pressure has become lower than the specified values.
5) When the swing lock switch is turned on, the parking brake starts to operate.
At the same time, pilot pressure works on both ends of the swing spool.
Page 12
Swing push
digging
When swing and arm operation are conducted simultaneously, swing pushing
function can be obtained by the swing override (arm parallel tandem) throttle
valve integrated in the control valve.
Page 16
Vibration
swingback
The anti reverse valve attached to the swing motor reduces swingbacks that occur
when the swing stops.
Swing parking
circuit
Arm Circuits
Arm-out circuit
Arm-in load
holding
Arm-in circuit
Switching between arm (1) and (2) spools makes the hydraulic oil flows merge,
achieving faster speed.
Page 18
Regeneration within the boom spool is used to increase speed and prevent cavitation.
Page 20
High pressure is suppressed with the bleed-off circuit and tilting is mitigated.
Page 22
Boom Circuits
Boom-up circuit
1) Switching between boom (1) and (2) spools makes hydraulic oil flows merge,
achieving faster speed.
2) When the arm is operated with the boom simultaneously, the flow volume to the
arm side is secured through the swing override (arm parallel tandem) variable
throttle valve.
Boom-down load
holding
1) The load holding valve that is integrated in the control valve reduces the natural
drop of the boom.
2) Boom-down pilot pressure enables boom-down operation by releasing the load
holding valve.
1) The regenerative circuit in the boom (1) spool works to improve the boom's
speed. It also prevents negative pressure from occurring.
2) Boom (2) does not operate.
Boom-down circuit
3) The bleed-off circuit in the spool reduces extra vibrations when the boom is
lowered.
Lep SC4608020-0EN
Page 24
Page 28
Page 30
Issued 03-07
Copyright
8020-4
Backup Circuits
Combined circuit
1) Backup circuit section is provided at control valve.

2) Switching over the spool in the control valve initiates internal confluence.
Page 32
Others
Cushion
A cushion valve with heat circuit is attached to the pilot line to reduce shocks when
the arm or boom movement stops.
Auto power boost
Through the engine load ratio and circuit pressure, the main relief pressure will be
raised from 31.4 MPa to 34.3 MPa.
This is designed to reduce power consumption by minimizing the flow of the

discharge from the hydraulic pump when operating with no load.
Negative control
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-5
This page has been left blank intentionally
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-6
Travel Circuits
1. High-speed Travel Circuit
With high speed travel, high speeds can be achieved by setting the two-level inclinatory angle of the travel motor to
the smaller angle side. The circuit has a travel motor that automatically switches over to lower speed by utilizing load
pressure on the travel motor when traveling at high speed.
Discharged oil from the hydraulic pump A1 enters the port P1 of control valve while discharged oil from the hydraulic
pump A2 enters the port P2 of control valve. Each flow goes into the travel motor by switching between the right and
left travel spools. By these flows, the machine travels forward and backward.
By operating the travel mode switch, electric signals are sent to the controller, and from the controller, electric signals
are sent to the solenoid valve for 2-speed (high speed) travel in the 6-way solenoid valve.
By the switchover of the solenoid valve, the original pilot pressure (3.9 MPa) from port C1 on the 6-way
solenoid valve enters port P of right and left travel motors via the rotating joint to set the inclinatory angle
of the travel motor to the smaller angle side, which enables high speeds.
pb6/B6.
pa6/A6.
pa1/A1.
pb1/B1.
10.
15.
21.
25/26.
52.
108.
A1.
C1.
S2.
Y2.
Y4.
RH forward travel
RH reverse travel
LH forward travel
LH reverse travel
Main hydraulic pump
Main control valve
Travel motors
Boom cylinders
Straight travel valve
Controller
Travel 2nd speed pilot
Travel mode switch
Pilot pressure solenoid valve
2 stage travel solenoid valve
Legend
Pressure Line
Pilot Pressure Line
Drain line
Tank line
Pilot tank line
Electric line
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-7
High Speed Travel Circuit
Boom cylinder
T1
T2
26
21
VA
VB
VB
VA
pb6
21
Travel
(Left)
pa6
B1
A1
pb1
pa1
Switch panel
S2
Travel
(Right)
B6
A6
Travel motor
25
Straight travel valve 108
TRAVEL
P
2-speed travel
Lever lock
P1
P2
Control valve
15
Y2
C1
A1
Controller
P
Y4
A1
52
6-way solenoid valve
10
A2
A3
Hydraulic pump
330.1.03.03.23A2
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-8
2. Low Speed Travel Circuit

The two-level inclinatory angle in the travel motor is set to the larger angle side. When the travel status is set to high
speed and the key switch is turned off and turned on again, the speed setting will always return to low speed.
Discharged oil from the hydraulic pump A1 enters the port P1 of control valve while discharged oil from the hydraulic
pump A2 enters the port P2 of control valve. Each flow goes into the travel motor by switching between the right and
left travel spools. By these flows, the machine travels forward and backward.
The solenoid valve for high speed travel is turned off and the oil in port P of the travel motor enters the tank line and
establishes a connection. As a result, the inclinatory angle of the travel motor is set to the larger angle side.
pb6/B6.
pa6/A6.
pa1/A1.
pb1/B1.
10.
15.
21.
25/26.
52.
108.
A1.
C1.
S2.
Y2.
Y4.
RH forward travel
RH reverse travel
LH forward travel
LH reverse travel
Main hydraulic pump
Main control valve
Travel motors
Boom cylinders
Controller
Travel mode switch
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-9
Low Speed Travel Circuit
Boom cylinder
T1
T2
26
21
VA
VB
VB
VA
pb6
21
Travel
(Left)
pa6
B1
A1
pb1
pa1
Switch panel
S2
Travel
(Right)
B6
A6
Travel motor
25
TRAVEL
P
2-speed travel
P1
Lever lock
P2
Control valve
15
Y2
C1
A1
Controller
P
Y4
A1
52
10
A2
A3
Hydraulic pump
330.1.03.03.23B2
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-10
3. Straight Travel Circuit

As an example, we describe the operation where travel and boom up are operated at the same time.
The pilot oil pressure enters from port PP of the control valve and communicates with the tank side via passages of
travel spool and spools for attachments (boom, arm, bucket and swing). When travel and boom-up operations are performed simultaneously, all circuits, which have been communicating with the tank, will be shut off by spools. This
makes pilot pressure oil entered from the port PP to lose where to flow and original pressure (3.9 MPa) switches over
the straight travel selector valve. The pressure works to the pilot chamber in straight travel valve allowing the valve to
be switched over.
As the result of the switchover of the straight travel valve, the pressurized oil in the control valve P1 drives the right
and left travel motors and the pressurized oil in the control valve P2 drives the attachments. The right and left pressures become equal because one pump drives both the right and left motors. This realizes straight travel. Additionally,
extra hydraulic oil from P2 is supplied via the check with travel confluence restriction to the travel side, and speed
reduction is minimized. The same theory applies and the circuits operate the same way when upper actuators other
than boom and travel are operated at the same time.
pb6/B6.
pa6/A6.
pb1/B1.
pa1/A1.
10.
15.
21.
25/26.
52.
108.
A1.
C1.
S2.
Y2.
Y4.
RH forward travel
RH reverse travel
LH forward travel
LH reverse travel
Main hydraulic pump
Main control valve
Travel motors
Boom cylinders
6 Solenoid valve bank
Computer / Controller
Travel mode switch
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-11
Straight Travel Circuit
Boom cylinder
T1
T2
25
26
VA
VB
VB
VA
Pa3
A7
B7
pb7
pa7
Pb3
Travel motor
21
Travel
(Left)
21
Travel
(Right)
pb6
pa6
B1
A1
pb1
pa1
Switch panel
B6
A6
TRAVEL
S2
P1
Lever lock
2-speed travel
T
Y2
PP
P2
valve
15
C1
Controller
A1
Y4
A1
52
A2
A3
10 Hydraulic pump
330.1.03.03.23C2
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-12
Swing Circuits
1. Swing Parking Circuit (Lever in Neutral / Swing Locked)
When the engine is started and the swing lever is in neutral, the swing brake solenoid valve becomes turned on (24 V
input) and the swing parking brake is activated.
When the swing lock switch is on, even if the swing pressure switch or attachment pressure switch is turned on, the
swing lock switch overrides and the parking brake remains unreleased. Since pressure oil out of the port C5 of 6-way
solenoid valve works on both sides of the swing spool while the swing is being locked, the spool in the control valve
will not be switched over even if the swing control lever is engaged.
pb2/B2.
pa2/A2.
10.
15.
22.
27.
54.
61.
A1.
B22.
B26.
B42.
B44.
C2.
C5.
S8.
Y1.
Y2.
Y3.
LH swing
RH swing
Main hydraulic pump
Main control valve
Swing motor
Arm cylinder
Swing control valve
Controller
Swing pilot pressure switch
Upper pilot pressure switch
Pump pressure sensor P1
Swing brake pilot
Swing shut-off pilot
Swing brake switch
Swing pilot shut-off solenoid valve
Swing brake solenoid valve
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-13
Swing parking circuit (Lever in neutral / Swing locked)

Swing motor
22
27
Arm cylinder
pb2
pa2
Shuttle
valve 2S
3S 1S
Remote control valve 54

Pressure B44
sensor
Y2
B42
Swing
pressure
switch
Pressure
sensor
Attachment
pressure B26
switch
B22
C2
15
Y3
Switch panel
swing lock
Swing brake
S8
C5
A1
A2
A3
Hydraulic pump
Y1
Controller
10
52
A1
330.1.03.04.24A2
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-14
2. Swing Parking Circuit (Brake Released)

When the swing pressure switch is turned on by operating the lever, output to the swing brake solenoid valve from the
controller is turned off and the swing parking brake is released by pilot pressure. Also, in order to prevent brake dragging caused by swing lateral force that is generated when digging attachments are moved with the swing lever being
in neutral, a mechanism which senses main pressure and releases the parking brake is introduced. Signals from the
pressure sensor on port pr1 or port pr2 of the control valve enter the controller. When either pressure reaches 15
MPa, the output to swing brake solenoid valve from the controller is turned off. This releases the swing parking brake.
When the pressure switch for attachments is kept off for more than 5 seconds, the swing pressure switch will be
turned off. Then 5 seconds after the pressure of the control valve pr1 or pr2 becomes 15 MPa or less, the solenoid
valve turns on and the swing parking brake starts operating. When the pressure on G4 or G5 becomes 15 MPa or
more, the swing brake is released. However, if the attachment switch was kept off for more than 5 seconds, the swing
parking brake works. (When traveling)
Key switch
Swing
pressure
switch
Pressure received on
pr1 or pr2
pressure sensor
Swing brake
solenoid valve
Swing motor
parking brake
OFF
OFF
OFF
Operates
15 MPa or less
ON
Operates
OFF
Released
Turns on 5 seconds
after attachment
pressure switch
is turned OFF.
Operates
15 MPa or less
OFF
Released
15 MPa or more
OFF
Released
OFF
ON
ON
pb2/B2.
pa2/A2.
10.
15.
22.
27.
54.
52.
A1.
B22.
B26.
B42.
B44.
C2.
S8.
Y2.
Y3.
15 MPa or more
LH swing
RH swing
Main hydraulic pump
Main control valve
Swing motor
Arm cylinder
Swing control valve
Controller
Swing brake pilot
Swing brake switch
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-15
Swing Parking Circuit (Brake Released)
Swing motor
A
22
B
T1
Pc5
27
Arm cylinder
pc4
B2
A2
pb2
pa2
Shuttle
valve
Remote control valve
2S
54
Pressure
B44
sensor
S2
S3
Y2
3
Lever lock
B42
Swing
pressure
switch
P1
PP PA
P
P2
Pressure
sensor
Attachment
pressure B26
switch
B22
Control valve
15
P
C2
Y3
Switch panel
swing lock
Swing brake
A1
S8
A2
A3
Hydraulic pump
Controller
10
52
A1
330.1.03.04.24B2
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-16
3. Swing Push Digging

The swing pilot pressure is supplied to port pc4 via the shuttle valve and enables the swing priority variable restriction
to be held to the right-hand side. Putting restriction on the parallel circuit secures swing force for enforced digging
operation with raised swing pressure even when the arm and swing are operated at the same time.
pb2/B2.
pa2/A2.
10.
15.
22.
27.
54.
52.
A1.
B22.
B26.
B42.
B44.
C2.
S8.
Y2.
Y3.
LH swing
RH swing
Main hydraulic pump
Main control valve
Swing motor
Arm cylinder
Swing control valve
Computer / Controller
Swing brake pilot
Swing brake switch
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-17
Swing Push Digging
Swing motor
A
22
B
Arm cylinder
pc1
B5
A5
27
pb5
pa5-1
pa5-2
pc4
pb9
pa9
B2
pb2 A2
pa2
Shuttle 2S
valve
54
1S
Pressure
B44
sensor
S2
S3
Y2
2
Lever lock
B42
2
Swing
pressure
switch
P2
P1
Pressure
sensor
Attachment
pressure B26
6
switch
B22
Control valve
15
P
C2
Y3
Switch panel
swing lock
Swing brake
A1
S8
A2
A3
Hydraulic pump
Controller
10
52
A1
330.1.03.04.24C2
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-18
Arm Circuits
1. Arm Out Circuit
Oil discharged from hydraulic pump A1 is supplied to the arm (1) spool through the center bypass oil passage in the
control valve. Oil discharged from hydraulic pump A2 is also supplied to the arm (2) spool through the parallel oil passage, and merges at the downstream of the arm (1) spool, then flows into the rod side of the arm cylinder via the load
holding valve. Oil returning from the bottom returns to the tank oil passage via the arm (1) and (2) spools.
pa5/A5.
pb5/B5.
pa9.
pb9.
10.
15.
25/26.
27.
54.
57.
Retracting the arm (dipper) (Arm 1)

Extending the arm (dipper)(Arm 1)
Extending the arm (dipper) (Arm 2)
Main hydraulic pump
Main control valve
Boom cylinders
Arm (Dipper) cylinder
Arm (Dipper) control lever
Boom and arm (dipper) control shock absorber
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-19
Arm Out circuit
Boom cylinder
T2
26
27
25
B5
A5
pb5
Arm
cylinder
pb9
pa5-1
pa5-2
pa9
Cushion valve
15
P2
P1
Control valve
D
A1
57
A2
A3
54
2
4
T
Hydraulic pump
10
330.1.03.06.23A2
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-20
2. Arm-In Load Holding

When the arm is in neutral, oil on the arm cylinder rod side is sealed by the load holding valve check. This mechanism
reduces internal leakage from the main spool.
When the arm-in is operated, the pilot pressure enters port pa5 of the control valve and moves arm (1) spool to the
arm-in side. Also, the pilot pressure separated from port pa5 enters port pc1 and moves the load holding valve spool
to the right. Through this mechanism, the oil in the spring chamber of the load holding valve check is connected to the
tank line passing the load holding valve spool. As a result, the pressure on the spring chamber decreases and the
load holding valve check is released. The hydraulic oil in the rod of the arm cylinder is returned to the tank line, the
arm cylinder extends and the arm moves in.
pa5/A5.
pb5/B5.
pa9.
pb9.
10.
15.
25/26.
27.
54.
57.

Main hydraulic pump
Main control valve
Boom cylinders
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-21
Arm-In Load Holding
Boom cylinder
T1
DR1'
pc1
B5
A5
pb5
27
Arm
cylinder
DR1'
26
25
ARM
pb9
pa5-1
pa5-2
Detail
pa9
DR1
Load holding
valve spool
pc1
Load holding
valve check
B5
Arm(2)
Arm(1)
P2
P1
54
Cushion valve
D
A1
57
Control valve 15
A2
A3
Hydraulic pump
10
330.1.03.06.23B2
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-22
3. Arm-In Circuit
For arm-in operation, pilot pressure is supplied to port pa5 and pa9 of the control valve and the arm spool
moves to the arm-in side.
At the same time, the arm load holding valve is released by the pilot pressure, and the discharged oil on
the cylinder rod side is restricted by the forced regenerative release valve. This forces the returned oil to be
regenerated into the cylinder bottom side via the check within arm (1) spool, securing the arm speeds
required for floor digging work. When the load pressure rises on the cylinder bottom side, the forced regenerative release valve switches over to the large diameter restriction side. As a result, the orifice for return
becomes large and returned oil on the rod side stops recycling.
pa5/A5.
pb5/B5.
pa9.
pb9.
10.
15.
25/26.
27.
54.
57.

Main hydraulic pump
Main control valve
Boom cylinders
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-23
Arm-In Circuit
Boom cylinder
T1
pc1
B5
A5
pb5
27
Arm
cylinder
26
25
pb9
pa5-1
pa5-2
pa9
Detail
B5
H/V
Load holding
valve check
A5
pb5
Forced regenerative
release valve
Cushion valve
D
A1
57
54
Control valve 15
P2
P1
A2
A3
Hydraulic pump
10
330.1.03.06.23C2
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-24
Boom Circuits
1. Boom-Up Circuit (Single)
Oil discharged from hydraulic pump A1 is supplied to the boom (2) spool from the parallel oil passage via
the control valve and merges at the downstream of the boom (1) spool. Oil discharged from hydraulic pump
A2 merges with the discharged oil from the boom (2) via the boom (1) spool through the parallel oil passage and flows into the bottom side of the boom cylinder via the holding valve.
pb3.
pa3.
pb7.
pa7.
10.
15.
25/26.
27.
28.
53.
57.
Lowering the boom (Boom 2)

Raising the boom (Boom 2)
Main hydraulic pump
Main control valve
Boom cylinders
Bucket cylinder
Boom control lever
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-25
Boom-Up Circuit (Single)
Boom cylinder
p
pc5
26
25
27
Arm
cylinder
A7
B7
pb7
pb3
pa3
pa7
P2
P1
Cushion valve G
15
H
A1
57
53
Control valve
A2
A3
Hydraulic pump
10
330.1.03.07.23A2
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-26
2. Boom-Up Circuit (Combined)

When floor digging operation is performed, the boom-up pilot pressure, which is supplied to port pc5, releases the
restriction on flow to the arm by moving the swing priority variable restriction to the left. This makes the arm move
smoothly.
pb3.
pa3.
pb7.
pa7.
pa5/A5.
pb5/B5.
pa9.
pb9.
10.
15.
25/26.
27.
53.
57.

Main hydraulic pump
Main control valve
Boom cylinders
Boom and bucket control lever
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-27
Boom-Up Circuit (Combined)
T1
Boom cylinder
p
pc5
pc1
B5
A5
pb5
27
Arm
cylinder
26
pa5-1
pa5-2
25
pb9
pa9
A7
B7
pb7
pa7
pb3
pa3
Cushion valve G
53
D
A2
A1
57
Control valve 15
P2
P1
A3
T A
Hydraulic pump
10
330.1.03.07.23B2
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-28
3. Boom-Down Load Holding

When the boom is in neutral, oil on the boom cylinder bottom side is sealed by the load holding valve
check. This mechanism reduces internal leakage from the main spool. For boom-down operation, the pilot
pressure enters port pb7 of the control valve and moves the spool of the control valve to the boom-down
side. Also, the pilot pressure enters port pc2 and moves the load holding valve spool to the left. Through
this mechanism, the oil in the spring chamber of the load holding valve check passes the load holding
valve spool creating a connection to the tank. Consequently, the pressure on the spring chamber
decreases and the load holding valve check is released. The hydraulic oil at the bottom side of the boom
cylinder is returned to the tank line, the rod of the boom cylinder shrinks, and the boom is lowered.
pb7/A7.
pa7/B7.
10.
15.
25/26.
27.
53.
57.

Main hydraulic pump
Main control valve
Boom cylinders
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-29
Boom-Down Load Holding
Boom cylinder
T2
26
27
25
Arm
cylinder
DR2''
pc2
A7
B7
pb7
pa7
Detail
Load holding
valve spool
DR2'
DR2
pc2
Load holding
valve check
Boom(2)
P2
53
Cushion valve
Control valve
Boom(1)
15
H
A2
57
A7
A3
F T
Hydraulic pump
10
330.1.03.07.23C2
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-30
4. Boom-Down Circuit
For boom-down operation, pilot pressure is supplied at port pb7 of the control valve, and the boom spool moves to the
boom-down side. At the same time, the pilot pressure opens the boom load holding valve and partially regenerates
the discharged oil from the bottom side of boom cylinder at the rod side via the check in the spool. (The lower the load
pressure of the cylinder rod side, the more the regenerated volume will be.)
When the boom is moved down as quickly as possible and the spool is at full stroke, negative pressure is generated
by bleed-off oil passage in the center bypass. High pressure generation is coutrolled, and vibration of the body is
reduced. Since the lack of oil is to be supplemented in the regenerative circuit, engine output can be effectively used.
pb7/A7.
pa7/B7.
10.
15.
25/26.
27.
53.
57.

Main hydraulic pump
Main control valve
Boom cylinders
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-31
Boom-Down Circuit
Boom cylinder
T2
26
25
27
Arm
cylinder
(1)
DR2'
pc2
A7
B7
pb7
pa7
Detail
Load holding
valve check
A7
H/V
B7
pb7
P2
Control valve
15
T2
P2
Cushion valve G
Bleed-off
H
A2
57
A3
53
F T
Hydraulic pump
10
330.1.03.07.23D2
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-32
Backup Circuits
1. Combined Circuit (Breaker Circuit)
Through remote control operation, the pilot pressure that is supplied to port pb4 of the control valve switches the
backup spool. This allows the discharged oil from the hydraulic pump A1 to flow into the breaker.
The pilot pressure operates the pressure switch at the same time. When the change-over switch in the cab is turned
to breaker mode, the controller directs the engine controller by signal from pressure switch so that the speed can
match the previously set engine speed.
Return oil from the breaker passes by way of 3-direction valve, and oil exceeding the set pressure flows from the stop
valve via the relief valve to return to the hydraulic oil tank.
pb4/B4.
pa4/A4.
10.
15.
72.
76.
78.
83.
A1.
B25.
S14.
W4.
Y9.
Breaker/Crusher circuit
Crusher Circuit
Main hydraulic pump
Main control valve
Control pedal
3-way selector
Return filter
Shut-off valve
Controller
Breaker/Crusher Switch
Breaker safety valve
Breaker/Crusher two flow solenoid valve
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-33
Combined Circuit (Breaker Circuit)
78
Filter
76
3-direction valve
1
83
83 Stop valve
W4
B4
Relief valve
83
pb4
pa4
72
Pressure
B25 switch
S1
P1
Control valve
A2
A1
15
Y9
Shuttle
valve
B1
S2
B2
Solenoid
valve
S14 Change-over switch
2
A1
Controller
A2
A3
1
Hydraulic pump
A1
Lep SC4608020-0EN
10
Issued 03-07
Copyright
8020-34
2. Combined Circuit (High Speed Confluence Circuit)

Through remote control operation, the pilot pressure that is supplied to port pa4 (or pb4) of the control valve switches
the backup spool. This allows the discharged oil from the hydraulic pump A1 to flow into the end attachment.
Turning the change-over switch in the cab to crusher (2) energizes the solenoid valve so that the valve is switched
over.
Pilot pressure divided via remote control valve is fed in the port pa10 by way of solenoid valve.
This changes over the spool to block the center-bypass circuit.
The blocked discharge oil of hydraulic pump A2 flows by way of merging passage to be combined together with the
discharged oil out of hydaulic pump A1 at upper flow course of the spare spool.
pb4/B4.
pa4/A4.
10.
15.
72.
76.
78.
83.
A1.
B25.
S14.
W4.
Y9.
Breaker/Crusher circuit
Crusher Circuit
Main hydraulic pump
Main control valve
Control pedal
3-way selector
Return filter
Shut-off valve
Controller
Breaker/Crusher Switch
Breaker safety valve
Breaker/Crusher two flow solenoid valve
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-35
Combined Circuit (High Speed Confluence Circuit)
78
T1
Filter
pa10
76
3-direction valve
83
83 Stop valve
W4
B4
A4
ppb4
pa4
Relief valve
83
72
Pressure
B25 switch
S1
A1
P1
P2
A2
P
Control valve 15
Y9
Shuttle
valve
B1 S2
B2
A Solenoid
valve
S14 Change-over switch
2
A1
Controller
A2
A3
1
Hydraulic pump
A1
10
330.1.03.09.17B2
Lep SC4608020-0EN
Issued 03-07
Copyright
8020-36
NOTES
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....................................................................................................................................................................................
....................................................................................................................................................................................
Lep SC4608020-0EN
Issued 03-07
8021
Copyright
Section
8021
TRAVEL HYDRAULIC MOTOR
ASSEMBLY AND DISASSEMBLY
CNH
Lep SM4608021-0EN

Printed in France
September 2007
Copyright
8021-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
SPECIAL TORQUES ..................................................................................................................................................... 2
SPECIAL TOOLS ........................................................................................................................................................... 3
TRAVEL MOTOR ........................................................................................................................................................... 5
Disassembly ............................................................................................................................................................... 7
Assembly ................................................................................................................................................................... 9
BEARING MEASUREMENT ........................................................................................................................................ 12
INSPECTION ............................................................................................................................................................... 13
OVERLOAD RELIEF VALVE ....................................................................................................................................... 16
Disassembly ............................................................................................................................................................. 16
TROUBLESHOOTING ................................................................................................................................................. 17
SPECIFICATIONS
See Section 1002.
SPECIAL TORQUES
Screw (56) ........................................................................................................32432.4 Nm (238.97 lbf-ft)(23.90 lbf-ft)
Pilot valve plug (35) ............................................................................................. 49 - 58.8 Nm (36.14 lbf-ft - 43.37 lbf-ft)
Overload relief valve (57) ................................................................................... 98.1 - 118 Nm (72.35 lbf-ft - 87.03 lbf-ft)
Plug (29) ......................................................................................................... 441 - 446 Nm (325.26 lbf-ft - 228.95 lbf-ft)
Plug (42) ......................................................................................................................................... 14.7 Nm (10.84 lbf-ft)
Plug (38) ......................................................................................................................................... 29.4 Nm (21.68 lbf-ft)
Plug (60).......................................................................................................................................... 98.1 Nm (72.35 lbf-ft)
Lep SM4608021-0EN
Issued 09-07
Copyright
8021-3
SPECIAL TOOLS
A
C
D
Mount metal (2 pieces)

A
160 mm (6.30 in)
B
70 mm (2.75 in)
C
20 mm (0.79 in)
CRPH06D006A
CRPH06D001A
D
E
100 mm (3.94 in)

37 mm (1.46 in)
Jig for inserting oil seal

A
100 mm (3.94 in)
B
7.7 mm (0.30 in)
C
B E
C
D
D
E
67.5 mm (2.66 in) F
90 mm (3.54 in)
more than10 mm (0.40
in)
R 0. 5 (0.01 in)
A
A
B C
F
G
D
C B
E
D
CRPH06D002A
Jig for pulling out brake piston (2 pieces)

A
12 mm
E 100 mm (3.94 in)
(0.47 in)
B
24 mm F 60 mm (2.36 in)
(0.94 in)
C
40 mm G 6.5 mm (0.26 in)
(1.57 in)
D
20 mm
H Hex.socket head bolt 2-M6 x 100
(0.79 in)
Lep SM4608021-0EN
CRPH06D004A
Jig for inserting rear bearing

A
120 mm (4.72 in)
C
B
36 mm (1.42 in) D
42 mm (1.65 in)
3 mm (0.12 in)
Issued 09-07
Copyright
8021-4
E
F
B
A
CRPH06D005A
Guide pin for rear cover (2 pieces)

A
100 mm (3.94 in)
D
M 18
B
32 mm (1.26 in)
E
R2
C
25 mm (0.98 in)
F
10
A B C D
G
H
J
I
K
L
CRPH06D006B
Jig for inserting brake piston

A
280 mm
G
2 - M 18 x 35
(11.02 in)
P. C.D. 251 mm
2 - 20 drill hole
(9.88 in)
215 mm
15 mm (0.59 in)
(8.46 in)
195 mm
50 mm (1.97 in)
(7.68 in)
21 mm (0.83 in)
10 - plain washer
10 mm (0.39 in)
18 mm (0.71 in)
2 - M18 x 50
Lep SM4608021-0EN
Issued 09-07
Copyright
8021-5
TRAVEL MOTOR
Description
48
43
49 47 46
55 24 53 25 44 45 42
5
6
2
52
51
58
38
59
4
39
54
10
11
13
1 16 12 15 14 17
20 22 23 50
18
36
31
19
21 56
33 32 34 35 36
37
48
57
61 60
29
30
28
27
26 40 41 42
43
330.7.02.02.37A1
Lep SM4608021-0EN
Issued 09-07
Copyright
8021-6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
CASING
PLUG
OIL SEAL
CIRCULAR SNAP RING
EXPANDER PLUG
INCLINED PISTON
PISTON SEAL
STEEL BALL
SHAFT
BEARING
PIVOT
SHOE PLATE
CYLINDER BLOCK
CYLINDER SPRING
SPRING HOLDER
BALL JOINT
SHOE RETAINER
PISTON ASSEMBLY
SEPARATOR PLATE
FRICTION PLATE
BRAKE PISTON
O-RING (SMALL)
O-RING (LARGE)
REAR COVER
PLUG
SPOOL ASSEMBLY
SPRING HOLDER
SPRING
PLUG
O-RING
Lep SM4608021-0EN
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
PILOT VALVE SPOOL

PIN
SPRING HOLDER
SPRING
PILOT VALVE PLUG
O-RING
CONNECTOR
PLUG
O-RING
RESTRICTOR (BRAKE VALVE)
RESTRICTOR SPRING (BRAKE VALVE)
PLUG
O-RING
CHECK VALVE
CHECK VALVE SPRING
RESTRICTOR (0.6)
O-RING
RESTRICTOR (0.8)
O-RING
O-RING
BEARING
SHIM
PARALLEL PIN
VALVE PLATE
BRAKE SPRING
SCREW
OVERLOAD RELIEF VALVE
COUPLING
RETAINING RING
PLUG
O-RING
Issued 09-07
Copyright
8021-7
Disassembly
General precautions
1. Hydraulic devices are made of precision components in general and structurally have small tolerances. Disassembling/assembling must be done in
a clean area free of dust. Tools and cleaning oil
must also be clean and must be handled with care.
2. If devices are removed from the main machine, first
clean the surrounding areas of the port, then plug
the ports and handle with utmost care to keep dust/
water from entering the inside.
3. Review the sectional drawings prior to disassembling and obtain the parts required according to the
specific purpose/scope of the job. Do not reuse
seals and O-rings that have been disassembled.
Also, some parts must be replaced as subassembly
because those parts are not supplied separately.
4. Pistons and cylinders, when they are brand new, do
not need to be assemblied in a particular order.
When disassembling, however, they need to be
marked if they are to be used again. Before removing the pistons from the cylinders, mark them all so
they can be put together in the exact order they
were assemblied in originally.
WARNING: Keep hands and fingers away from small gaps or crevices among parts. Lifted loads also require
extra attention since they may fall on your feet.
NOTE: the numbers in brackets refer to the drawing on

page 3.
STEP 7
STEP 1
Guide pin
Remove the plug (29) and O-ring (30).
STEP 2
Remove spring (28), spring holder (27) and spool
assembly (26).
Put the mating mark on both spool assembly (26) and
rear cover (24) so that spool assembly (26) should not
be reversed on re-assembling.
It is impossible to disassemble this spool assembly (26)
further because spool assembly (26) is fixed by adhesive.
Hole for releasing

brake (left)
49
47 55 24
52
STEP 3
Remove plug (42), O-ring (43), check restrictor spring
(41) and restrictor (40).
STEP 4
Remove overload relief valves (57).
When removing overload relief valve (57), valve seat
(57-3) easily comes off, so take great care not to fall
into the rear cover (24) or lose.
13 54
50 51 56
STEP 5
Remove pilot valve plug (35) and then, remove O-ring
(36), pilot valve spring (34), spring holder (33), pilot
valve spool (31) and pin (32).
STEP 6
Remove coupling (58).
Lep SM4608021-0EN
330.7.02.02.37D1
Place the motor with the shaft horizontal, remove Hex.

socket head bolts Ml8 x 50 (56) of rear cover (24) leaving two on diagonally upper and lower position.
Issued 09-07
Copyright
8021-8
STEP 8
STEP 15
Install two guide pins diagonally into rear cover (24).

(Purpose: Prevention of falling rear cover).
STEP 9
19
Loosen slowly and simultaneously the remaining two

Hex. socket head bolts Ml8 x 50 (56).
20
13
STEP 10
Remove rear cover (24) and brake springs (55) taking
care cylinder block (13) is not coming out stuck with
rear cover (24).
18
STEP 11
Keep the cylinder block (13) in its position and remove
the valve plate (54).
Mark the valve plate (54) and the rear cover (24) to differentiate the front from the back at assembly.
Paper pipe
STEP 12
Press the cylinder block (13) onto the pressing jig using
the removed screw (56) to push out the inner race of
the rear bearing (51).
Matching mark
16 15 17 14
STEP 13
330.7.02.02.37.9
Take a soft material like a sheet of paper and roll it into

a tube to use for marking without scratching parts.
Insert this into the piston (18) hole and mark the circumference of the cylinder block (13).
STEP 16
Remove the cylinder block (13), the spring bearing (15)
and the cylinder spring (14).
STEP 17
Remove the separator plate (19) and the friction plate
(20).
Place the gear (bearing) extractor inner race of the
bearing (51) to remove the bearing.
STEP 14
Hole for releasing brake
STEP 18
Remove the nine piston assemblies (18), the shoe
retainers (17) and the ball joints (16), all at the same
time.
NOTE: The procedures above are for the motor as a
single unit, but can also be applied on models with
reduction gears. The disassembling for those can be
conducted in the same manner. The job with theses
models may be easier because there is less vibration
due to larger shafts.
Secure the brake piston (21) with hand and push the
piston (21) out by supplying air through the brake
release oil hole.
WARNING: The procedure requires extra attention: the piston may pop out due to the air pressure.
Lep SM4608021-0EN
Issued 09-07
Copyright
8021-9
Assembly
STEP 19
General precautions
3 10 1
6
12
1. Clean parts well with cleaning oil and blow dry with
air.
2. Apply clean hydraulic oil to sliding parts prior to
assembling.
WARNING: Keep hands and fingers away from

small gaps or crevices among parts. Lifted
loads also require extra attention since they
may fall on your feet.
11
9
STEP 1
330.7.02.02.37I1
Remove the shoe plate (12).
STEP 20
Do not remove the inclined piston (6).

In the event that this must come out, secure it by hand,
push out by blowing air into the hole.
STEP 21
The shaft (9) will come out on its own.
STEP 22
Remove the retaining ring (4) and take out the oil seal
(3).
STEP 23
CS02B533
Apply grease to the outer perimeter of the oil seal (3) as

well as to the inner perimeter of the casing (1). Use jigs
to gently and evenly tap the oil seal (3) into casing (1)
without slanting.
STEP 2
When changing the bearings, inner and outer races are

also to be removed with a bearing puller. Each must be
replaced as an assembly.
3 10 1
6
12
330.7.02.02.37I1
Secure the oil seal (3) with the snap ring (4).
Lep SM4608021-0EN
Issued 09-07
Copyright
8021-10
STEP 3
STEP 9
Insert the outer race of the bearing (10) into casing (1)
and press fit the inner race into the shaft (9).
Heating the inner race to approximately 100C facilitates the insertion process here.
Plastic hammer
1 18 19 20
22 23 56
STEP 4
Place the shaft (9) into the casing (1). Prior to this procedure, grease must be applied to the working surface
that contacts the seal (3).
51
STEP 5
Insert the inclined piston (6).
STEP 6
Insert the pivot (11) into the side where the markings
match. Also, if the machine has been in use for a long
time prior to servicing, insert in the direction so the sliding traces on the spherical part of the shoe plate (12)
match the contact traces.
21
STEP 7
17 18 15 13
Jig for inserting

rear bearing
Or
Jig for inserting brake piston

10-Plain washer
12
330.7.02.02.37P1
Gently tap and insert the inner race of the rear bearing
(51) into the edge of the shaft (9), see jig for inserting
rear bearing on page 3.
16
9
14
13
1
330.7.02.02.37O1
Apply a liberal amount of grease to the spherical section of the shoe plate (12), then install.
STEP 8
Place the piston assembly (18), shoe retainer (17), ball
joint (16), spring (14) into the cylinder block (13) and
insert the whole assembly into the shaft (9). The piston
assembly (18) must be assembled into the original
hole.
Lep SM4608021-0EN
STEP 10
The separator plates (19) and the friction plates (20)
need to be installed alternately and completely. Start
with a separator plate (19) and finish with one also.
STEP 11
Insert the O-rings (22) and (23) into the brake piston
(21), then install the piston into the casing (1) using the
jig for inserting the brake piston, see on page 3.
Issued 09-07
Copyright
8021-11
STEP 12
STEP 18
49
47 55 24
52
Inserting spool assembly (26) to rear cover (24) coinciding mating mark made prior to disassembling, and
then assemble spring holder (27) and spring (28).
STEP 19
Assemble M 42 plug (29) with O-ring (30), tighten to
the torque specified on page 2.
58
59
13 54
50 51 56
330.7.02.02.37D1
Install two guide pins (B) diagonally on casing (1).(Purpose: Guide for installing rear cover)
Lay down rear cover (24) to mount valve plate (54)
coinciding mating mark made prior to disassembling
and also place brake springs (55) with ample grease to
be attached to rear cover (24) while assembling.
Also set shim (52), outer race of rear bearing (51) and
O-rings (50), (47), (49) on rear cover (24).
STEP 13
Insert rear cover (24) to casing (1) along the guide pin,
and install two Hex. socket head bolts M18 x 50 (56)
diagonally upper and lower position and tight them to
assemble rear cover (24) parallel.
Then, install the rest of Hex. socket head bolts M18 x
50 (56) and remove guide pin and install two the
remainder.
When removing outer race of rear bearing (51), install
shim (52) without fail.
Confirm that O-rings (47), (49), (50) are installed to rear
cover (24).
STEP 14
Assemble coupling (58).
STEP 15
Assemble spring (34), spring holder (33), pilot valve
spool (31) and pin (32) to rear cover (24), and then
install pilot valve plug (35) with O-ring (36), tighten to
the torque specified on page 2.
STEP 16
Assemble overload relief valves (57), tighten to the
torque specified on page 2.
STEP 17
Assemble restrictor (40) and restrictor spring (41) to
rear cover (24), and then install G/18 plug (42) with Oring (43), tighten to the torque specified on page 2.
Lep SM4608021-0EN
Issued 09-07
Copyright
8021-12
BEARING MEASUREMENT
F
9
10
51
52
24
330.7.02.02.37J
This work should be done only when you have changed bearings (10), (51), shaft (9), casing (1) or rear cover (24).
Measure the assembling width E
Take care not to incline shaft (9).
Measure the depth F of rear cover (24)
Measure them at crossed 4 places on the circuit, then calculate their mean value.
When thickness of shim (52) to be used is placed as S, the clearance Y can be calculated as follows:
Y=F-(E+S)
Select one or two shim (52) so as the clearance Y to come to 0-0.1 mm (clearance) on this unit.
Lep SM4608021-0EN
Issued 09-07
Copyright
8021-13
INSPECTION
Items to measure and
methods of measurement
1. Sliding surfaces on cylinder block,
valve plate and shoe plate
Measure the roughness of the sliding
surfaces of these parts using surface
roughness gauge.
Criterion and remedy

Table 2. Items and
what to be
inspected
Surface
roughness:
standard
Surface
roughness:
acceptable
limit
Remedy
Surface
roughness of
cylinder block,
valve plate and
shoe plate
0.4 Z or
below
3.0 Z or
below
Repair or
replace
Attention! Lapping is required to repair the surface roughness of

cylinder block and valve plate. (Lapping material: # 1200)
Measure the hardness of the sliding
surfaces of shoe plate using hardness
meter.
2. Clearance between piston and

cylinder block
Measure the outer diameter of piston
and the inner diameter of cylinder
using a micrometer at 3 locations at
least in the longitudinal direction.
The maximum outer diameter is
represented as d, minimum diameter
as d1, maximum hole diameter as D
and minimum diameter as D1.
Table 3. Items and

what to be
inspected
Hardness:
standard
Hardness:
acceptable
limit
Remedy
Shoe plate
HS78 or
above
HS74
Replace
Table 4. Items and

what to be
inspected
Standard
Remedy
value
Allowable
value
(in mm)
(in mm)
Outer diameter of
piston d-d1
0.01 mm
0.05 mm
Inner diameter of
cylinder bore D1D
0.01 mm
0.022 mm
0.037 to
0.047 mm
0.065 mm
Clearance D-d
Replace
piston or
cylinder
block
Attention! All 9 pistons must be replaced together if replacement is

necessary.
3. Looseness on piston and shoe
Hold the shoe on the surface plate
with jigs and pull out the piston
upwards to measure looseness d of
the piston and shoe.
Lep SM4608021-0EN
Table 5. Items and

what to be
inspected
Standard
dimensions
Looseness of the
crimping area of
piston and shoe
0 to 0.1 mm
(value in
mm)
Allowable
(value in
mm)
Remedy
0.5 mm
Replace
piston
Issued 09-07
Copyright
8021-14
Dial gauge
Piston
Jigs
Magnet
Shoe
Surface plate
Measurement
Looseness of crimping area
330-7-02-02-37T1

4. Negative braking force
When the assembling is complete,
measure the torque at start of
rotation by placing a torque wrench
at the end of the output shaft.

Table 6. Items and
what to be inspected
Standard
value (in mm)
Allowable
value (in mm)
Remedy
Brake torque
1.171 Nm
(0.863 lbf-ft)
1.055 Nm
(0.778 lbf-ft)
Separator plate
Friction plate
Spring
Replace all of
the above
Standard of replacing friction and separating plate.

When measuring parking brake torque, it needs to disassemble travelling
unit to motor and reduction gear portion, and it's so hard.
The right allowable value is a standard of replacing friction and separating
plate.
If it is impossible to disassemble travelling unit, refer to the right value.
Standard of replacing friction and separating plate
Measure the total thickness of 6 pieces of friction plate and 7 pieces of
separating plate.
And if the total thickness is below the following allowable value, replace all
separating and friction plates and springs.
5. Shaft
Use a roughness gauge and
measure the extent of wear on the
seal of the shaft.
6. Bearing
Replace bearings.
7. Spline
Replace parts when the wear of the
spline exceeds the allowable limit.
Lep SM4608021-0EN
Criteria:
33.04 mm (1.30 in)
Allowable Thickness:
31.5 mm (1.24 in)
Usable up to 0.05 mm of wear with steps.

Attention! Replace the oil seal (3) also when replacing the shaft.
Attention! The thickness of the shim (52) needs to be adjusted when
replacing the shaft.
The bearings (10 and 51) need to be replaced before the hour meter
records 10,000 hours of operation.
Attention! Replace the inner and the outer race also when replacing the
bearings.
Attention! The thickness of the shim (52) needs to be adjusted when
replacing the bearings.
The spline is reusable up to the 0.3 mm of wear with steps at the contact
surface.
Issued 09-07
Copyright
8021-15
8. Overload relief valve section
The pressure check and the
adjustment of the overload relief
section cannot be done unless the
applicable test bench is available.
Lep SM4608021-0EN

Replace as a subassembly every 10,000 hours according to the main
machines hour meter.
Issued 09-07
Copyright
8021-16

Disassembly
NOTE: As a rule, overload relief valve (57) should be handled as one service part. If there are any trouble on overload
relief valve (57), replace as an assembly.
57-3
57-2 57-1 57-12 57-13 57-4
57-9 57-8
57-12 57-10 57-11 57-6 57-7 57-5
CS02B539
NOTE: Valve seat (57-3) is fitted in bore of socket (571) at clearance fit.
When removing overload relief valve (57), valve seat
(57-3) easily comes off, so take great care not to los
NOTE: When assembling overload relief valve (57) to
rear cover (24), apply grease sufficiently on engagement part not to drop valve seat (57-3), tighten to the
torque specified on page 2.
GREASE
CRPH06D015A
Lep SM4608021-0EN
Issued 09-07
Copyright
8021-17
TROUBLESHOOTING
1.Hydraulic motor never starts
SYMPTOM
CAUSE
REMEDY
Pressure never
increases
Malfunction of built-in relief valve.
Repair or replace relief valve
Pressure increases
1.Parking brake is not released

Clogging of restrictor
1.After inspection of clogging, repair or

replace
2.Parking brake is not released

Spool is installed in wrong direction
2.Re-install the spool in correct direction
3.Stuck friction or separating plate of 3.Replace friction and separating plate

parking brake portion
4.Stuck brake piston
4.Repair outer dia. of brake piston or

replace It.
5.Seizure of sliding piston
5.Check, repair or replace piston shoe,

swash plate, cylinder block valve plate
etc.
6.Malfunction of spool:
- Stick between spool and body
- Clogging of restrictor
6.Repair or replace
2.Hydraulic motor rotates weakly

Set pressure of overload valve is
correct, but brake is released
belatedly
Malfunction of spool:
- Stick between spool and body
Repair or replace
Negative brake is released, but

motor is hard to start
High oil viscosity.
Raise oil temperature or change the

hydraulic oil
Negative brake is released, but

motor starts weakly
1.Negative brake is not completely 1.Check clogging of choke

released.
Clogging of choke of pressure release
passage
2.Relief valve catches small particles
2.Wash relief valve, check or replace

seat of it
3.Seizure of sliding portion
3.Check, repair or replace sliding portion
3.Drive shaft never rotate up to the set value
Rotation of drive shaft never

reaches the set value
1.Shortage of oil coming in
1.Check oil flow or hydraulic circuit to

motor.
2.Large wear or flaw made on shoe, cyl- 2.Check, repair or replace the parts
inder block or valve plate
Lep SM4608021-0EN
Issued 09-07
Copyright
8021-18
4.Brake refuses to work
SYMPTOM
Brake refuses to work
CAUSE
Malfunction of negative brake:
- Worn friction plate.
- Broken spring.
REMEDY
Check, repair or replace brake piston,
friction plate, spring, etc.
Repair or replace or clean up

Brake works on counter lever Malfunction of spool:
operation
- Stick between spool and body.
- Stick of check valve or that by small
particle.
- Clogging of restrictor.
5.Oil leakage
Oil leakage
1.Loose Hex. socket head bolt or plug
1.Fasten it with given torque
2.O-ring is torn off
2.Replace O-ring
3.Oil leaks inside gear casing
3.Replace oil seal
6.Would not shift from high to low
Would not shift from high to

low
Stick of spool of pilot valve
Replace pilot valve assembly.
7.Abnormal noise
Abnormal noise appear together Malfunction of spool:
with big vibration when brake is - Air is caught inside brake valve
slowly applied or oil is supplied to
Stick between spool and body
other circuits while motor is running
Bleed air
Repair or replace
8.Hunting occurs while descending the slope

Severe hunting while inching
Lep SM4608021-0EN
Malfunction of spool:
1) Stick between spool and body
1) Restrictor is not seated completely
Repair or replace
Interference with parking brake:

1) Permanent set or broken spring
Repair or replace
Issued 09-07
8022
Copyright
Section
8022
FAN MOTOR
REMOVAL AND INSTALATION
CNH
Lep SM4608022-0EN

Printed in France
September 2007
Copyright
8022-2
TABLE OF CONTENTS
FAN MOTOR................................................................................................................................................................... 3
Description ................................................................................................................................................................. 3
Removal ..................................................................................................................................................................... 4
Installation .................................................................................................................................................................. 4
Lep SM4608022-0EN
Issued 09-07
Copyright
8022-3
FAN MOTOR
Description
3
2
1
2
4
10
11
12
CRPH06B113G1
1
2
3
4
5
6
FAN MOTOR
PILOT VALVE ASSEMBLY
HOSE
HOSE
HUB
BOLT
Lep SM4608022-0EN
7
8
9
10
11
12
WASHER
VENTILATOR
BOLT
WASHER
BOLT
WASHER
Issued 09-07
Copyright
8022-4
Removal
STEP 7
STEP 1
CRPH06B114A
Label and disconnect the hoses (4).

JS00163A

STEP 2
STEP 3
STEP 8
Label and disconnect the electrical connections to the
pilot valve assembly (2).
STEP 9
Remove the bolt (6) and the washer (7) from the fan
motor (1) and remove the fan motor.
Installation
NOTE: When installing the fan motor on the machine,

operations:
CT05L063
Disconnect the earth cable (-) (1) from the battery.

Manual).
leaks.
necessary.
STEP 4
Refer to section 2001 and remove the radiateur and oilcooler assembly.
STEP 5
Remove the bolt (11) and the washer (12) fixing the
ventilator (8) and the hub (5) on the fan motor (1).
STEP 6
Remove the bolt (9) and the washer (10) fixing the
ventilator (8) on the hub (5), then remove the ventilator
and the hub.
Lep SM4608022-0EN
Issued 09-07
Copyright
8023
Section
8023
FAN MOTOR
CNH
Lep SM4608023-0EN

Printed in France
September 2007
Copyright
8023-2
TABLE OF CONTENTS
SPECIFICATIONS ........................................................................................................................................................... 2
PREPARATION BEFORE REMOVAL/INSTALLATION................................................................................................... 2
FAN MOTOR.................................................................................................................................................................... 3
Description ................................................................................................................................................................... 3
REPLACEMENT PROCEDURE FOR THE OIL SEAL..................................................................................................... 4
Disassembly ................................................................................................................................................................. 4
Assembly ..................................................................................................................................................................... 5
REPLACEMENT PROCEDURE FOR THE SUCTION SAFETY VALVE ......................................................................... 6
Disassembly ................................................................................................................................................................. 6
Assembly ..................................................................................................................................................................... 7
REPLACEMENT PROCEDURE FOR THE PILOT VALVE FOR THE REVERSING OPERATIONS .............................. 8
Disassembly ................................................................................................................................................................. 8
Assembly ..................................................................................................................................................................... 8
Lep SM4608023-0EN
Issued 09-07
Copyright
8023-3
FAN MOTOR
Description
2
4
CRPH06B035G01
1
2
3
4
5
SNAP RING
SPACER
OIL SEAL
PLUG
SPRING
Lep SM4608023-0EN
6
7
8
9
SAFETY VALVE
O-RING
PILOT VALVE ASSEMBLY
BOLT
Issued 09-07
Copyright
8023-4
REPLACEMENT PROCEDURE FOR THE OIL SEAL

Disassembly
STEP 3
2
NOTE: Precautions before starting the disassembly

work. Before starting the disassembly work, wash the
surfaces of the motor and the shaft so that foreign
substance may not enter into inside of the motor.
STEP 1
CRPH06B020A01
Remove the spacer (2).
STEP 4
CRPH06B018A01
Place the motor on the work bench so that its shaft

may be directed upward.
STEP 2
1
CRPH06B021A01
Using a gimlet type tool (ice pick, etc.), remove the

oil seal (3).
CRPH06B019A01
Using snap ring pliers, remove the snap ring (1).
CRPH06B022A01
WARNING: Be careful not to receive injury to your

fingers by the gimlet type tool (ice pick, etc).
Lep SM4608023-0EN
Issued 09-07
Copyright
8023-5
STEP 5
STEP 3
CRPH06B023A01
CRPH06B024A01
Remove the foreign substance remaining in the

seal groove to clean the groove completely.
NOTE: When cleaning, take care that foreign
matter will not enter the bearing.
Assembly
STEP 1
3
A
B
C
CRPH06B025A01
Install the oil seal into the seal groove using a

press-fitting tool.
(A) 5. 2 0. 1
(B) 26
(C) 44
CRPH06B022A01
After applying grease on the inside surfaces of the

lip of the oil seal (3), install the oil seal into the
shaft.
STEP 4
STEP 2
2
CRPH06B019A01
Using snap ring pliers, install the snap ring (1) into
the ring groove.
CRPH06B020A01
Install the spacer (2).
Lep SM4608023-0EN
NOTE: Check and make sure that the snap ring is

being inserted securely into the ring groove.
Issued 09-07
Copyright
8023-6
REPLACEMENT PROCEDURE FOR THE SUCTION SAFETY VALVE

Disassembly
STEP 2
STEP 1
5
6
CRPH06B028A01
CRPH06B026A01
NOTE: Precautions before starting the disassembly

work. Before starting the disassembly work, wash the
surfaces of the motor and the neighborhood of the plug
so that foreign substance may not enter into inside of
the valve.
Place the motor on the work bench so that its plug

may be directed sideway.
CRPH06B029A01
Remove the spring (5) and the safety valve (6).
STEP 3
CRPH06B027A01
CRPH06B030A01
Remove the foreign substance remaining on the

safety valve mounting surface to clean the surface
completely.
Lep SM4608023-0EN
Issued 09-07
Copyright
8023-7
Assembly
STEP 3
STEP 1
5
6
4
CRPH06B026A01
CRPH06B027A01
After applying the engine oil, install the safety

valve (6) and spring (5)
Tightening torque for the plug (4):

147 to 186.2 Nm (108 ~ 137 lb-ft).
STEP 2
CRPH06B031A01
Tighten the plug (4) after setting the O-ring (7) to

the plug.
NOTE: When carrying out the tightening work, fix to
stabilize the motor body using a press machine, etc.
Lep SM4608023-0EN
Issued 09-07
Copyright
8023-8
REPLACEMENT PROCEDURE FOR THE PILOT VALVE FOR THE REVERSING

OPERATIONS
Disassembly
Assembly
STEP 1
STEP 1
10
NOTE: Before starting the disassembly work, wash the

surfaces of the motor and the neighborhood of the pilot
valve so that foreign substance may not enter into the
motor body side.
11
12
8
CRPH06B034A01
Check the O-rings (10), (11) and (12) are installed

on the new pilot valve (8).
STEP 2
CRPH06B032A01
Place the motor on the work bench so that the pilot

valve may be directed sideway.
Remove 4 pcs. of the mounting bolts (9) and
remove the pilot valve (8).
STEP 2
9
CRPH06B032A01
Setting the pilot valve (8) to the motor body, tighten 4

pcs. of the mounting bolts (9) to a torque of 27.5 to 34.3
Nm (20 ~ 25 lb-ft).
CRPH06B033A01
Clean the pilot valve mounting surface completely.
Lep SM4608023-0EN
Issued 09-07
Copyright
Section
FAN PUMP
REMOVAL, DISASSEMBLY, ASSEMBLY
AND INSTALLATION
CNH
Lep SM4608024-0EN

Printed in France
September 2007
8024
8024
Copyright
8024-2
TABLE OF CONTENTS
SPECIAL TOOLS ............................................................................................................................................................. 2
FAN PUMP....................................................................................................................................................................... 3
Description ................................................................................................................................................................... 3
Removal ....................................................................................................................................................................... 4
Disassembly................................................................................................................................................................. 5
Assembly ..................................................................................................................................................................... 6
Installation ..................................................................................................................................................................... 7
SPECIAL TOOLS
CRPH06B047A01
JIG: 39mm (Outside Dia). x 29mm (Inside Dia) x

100mm (Length).
Lep SM4608024-0EN
Issued 09-07
Copyright
8024-3
FAN PUMP
Description
3
2
1
CRPH06B037G01
1
2
3
SNAP RING
OIL SEAL
PLATE
Lep SM4608024-0EN
Issued 09-07
Copyright
8024-4
FAN PUMP
Removal
STEP 1
JS00163A1

STEP 2
hydraulic reservoir (see section 8000).
STEP 3
1
3
CRPH06B040A01
Label and disconnect the hoses (1) and (2).

Remove the screws (3) fixing the fan pump and remove
the fan pump.
Lep SM4608024-0EN
Issued 09-07
Copyright
8024-5
Disassembly
STEP 3
NOTE: Before decomposition, please wash the pump

surface and the spline shaft, and make sure that a
forign object should not go into the inside of a pump.
STEP 1
2
CRPH06B043A01
Remove the oil seal (2) using a gimlet (Ice Pick).

NOTE: Don't make a scrath on the shaft surface by a
gimlet. Be careful not injured using a gimlet (Ice Pick).
CRPH06B03A01
STEP 4
Put the pump on a work bench. Which the spline

shaft to be right overhead.
STEP 2
3
1
CRPH06B044A01
CRPH06B042A01
Remove the snap ring (1) using a snap ring plier.
CRPH06B045A01
Remove the plate (3) and take away the rubbish in

the seal housing.
Lep SM4608024-0EN
Issued 09-07
Copyright
8024-6
Assembly
STEP 1
CRPH06B050A01
CRPH06B044A01
Clean up the plate (3) and install it in the bottom of

seal housing.
STEP 2
CRPH06B051A01
Install the oil seal (2) using the jig (see special tool
page 2).
STEP 3
CRPH06B048A01
CRPH06B042A01
CRPH06B049A01
Lep SM4608024-0EN
Install the snap ring (1) using a snap ring plier.
Issued 09-07
Copyright
8024-7
Installation
NOTE: When installing the fan pump on the machine,
operations:
Manual).
leaks.
necessary.
Lep SM4608024-0EN
Issued 09-07
Copyright
8024-8
NOTES
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
Lep SM4608024-0EN
Issued 09-07
Copyright
Section
8030
CNH
Lep SC4608030-0EN

Printed in France
March 2007
8030
HYDRAULIC COMPONENT FUNCTIONS
Copyright
8030-2
TABLE OF CONTENTS
HYDRAULIC PUMP ................................................................................................................................................ 3
CONTROL VALVE .................................................................................................................................................. 6
SWING UNIT......................................................................................................................................................... 23
TRAVEL UNIT ....................................................................................................................................................... 28
FAN MOTOR FOR HYDRAULIC DRIVE .............................................................................................................. 40
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-3
HYDRAULIC PUMP
Structure and Principle of Operation
This pump couples two pumps placed on the same axis with the 1st gear (114) and distributes the rotational force to
the different axes. The rotational force transmitted from the motor to the front side drive shaft (111) drives the two
pumps and also drives the backup pump installed on the other axis simultaneously.
This pump consists of four major sections: the rotary group that is the main part of the pump governing the rotation,
the swash plate group that adjusts discharge rate, the valve block group that switches between intake and discharge
of oil, and the PTO group that transmits the rotational force from the gear pump drive shaft.
The rotary group is composed of the drive shaft F (111), cylinder block (012), piston shoes (151 and 152), retainer
(153), spherical bush (156) and cylinder spring (157).
Both ends of the drive shaft are supported by bearings (123 and 124).
The shoe forms a spherical joint crimped by a piston and contains a pocket area in order to reduce the thrust force
generated by the loading pressure and to balance the oil pressure so that it slides lightly on the shoe plate (211). The
subgroup of the piston shoe is pressed on the shoe plate by the cylinder spring via the retainer and spherical bushing
in order to facilitate its smooth movement on the shoe plate. The cylinder block is also pressed on the valve plate
(313) by a cylinder spring. The swash plate group consists of the swash plate (212), shoe plate (211), swash plate
support (251), tilting bush (214), tilting pin (531), and servo piston (532). The swash plate is supported on the swash
plate support by the cylindrical part formed on the opposite side of the shoe sliding side.
The hydraulic force, which is controlled by the regulator, is directed into the hydraulic compartment located on both
sides of the servo piston. This causes the servo piston to move back and forth. The movement of the servo piston
makes the swash plate swing on the swash plate support via the spherical part of the leaning pin and changes the
angle of incline ().
The valve block group consists of the valve block (312), valve plate (313) and valve plate pin (885). The valve plate,
which has two claw-shaped ports, is installed on the valve block. It supplies oil to and recovers oil from the cylinder
block.
Oil that is switched by the valve plate enters the external piping through the valve block.
The PTO group consists of the 1st gear (114), 2nd gear (117) and 3rd gear (118). The 2nd and 3rd gears are supported by bearings (126 and 125) and are installed on the valve block.
When the drive shaft is driven by the motor (electric motor, engine, etc.), the cylinder block rotates simultaneously via
the spline connection. When the swash plate is inclined, the piston located inside the cylinder block moves back and
forth with respect to the cylinder as it rotates with the cylinder block. Specifically, when the cylinder block rotates one
full turn, the piston moves away from the valve plate (oil is drawn in) during the first 180 degrees and moves towards
the valve plate (oil is discharged) during the remaining 180 degrees. When the angle of the swash plate is zero, the
piston does not move and oil is not discharged.
The rotation of the drive shaft is led to the 1st gear (114), transmitted to the 3rd gear (118) through the 2nd gear
(117) and drives the backup pump connected to the 3rd gear.
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-4
Hydraulic pump drawing
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-5
Description
No.
04
PART NAME
QTY.
GEAR PUMP
1ST
CONSTITUENT PART(QTY)
ZX15LPRZ2
05
PTO ASS'Y
1ST
011
PISTON ASS'Y
2ST
151(9PC), 152(9PC)
013
CYLINDER(R) ASS'Y
1ST
141(1PC), 313(1PC)
014
CYLINDER(L) ASS'Y
1ST
141(1PC), 314(1PC)
030
SWASH PLATE ASS'Y
2ST
212(1PC), 214(1PC)
041
CHECK VALVE 1 ASS'Y
2ST
541(1PC), 543(1PC), 545(1PC)
042
CHECK VALVE 3 ASS'Y
2ST
541(1PC), 544(1PC), 545(1PC)
079
PROPORTINAL REDUCING
VALVE ASS'Y
1ST
KDRDE5KR-V3-V
NO.
111
113
114
123
124
127
012
151
152
153
156
157
211
212
214
251
261
263
271
312
313
314
PARTNAME
DRIVE SHAFT(F)
DRIVE SHAFT(R)
GEAR 1ST
ROLLER BEARING
NEEDLE BEARING
BEARING SPACER
CYLINDER BLOCK
PISTON
SHOE
RETAINER
SPHERICAL BUSH
CYLINDER SPRING
SHOE PLATE
SWASH PLATE
TILTING BUSH
SWASH PLATE
SUPPORT
SEAL COVER(F)
SEAL COVER(R)
PUMP CASING
VALVE BLOCK
VALVE PLATE(R)
VALVE PLATE(L)
Lep SC4608030-0EN
QTY
1
1
1
2
2
3
2
18
18
2
2
18
2
2
2
NO.
401
406
466
468
490
492
531
532
534
535
541
543
544
545
548
PARTNAME
HEX SOCKET HEAD BOLT
PLUG
PLUG
PLUG
PLUG
TILTING PIN
SERVO PISTON
STOPPER(L)
STOPPER(S)
SEAT
STOPPER 1
STOPPER 2
STEEL BALL
FEED BACK PIN
QTY
8
8
2
4
27
12
2
2
2
2
4
2
2
4
2
702
O-RING
1
1
2
1
1
1
710
714
717
719
724
725
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
2
1
2
2
16
6
NO.
728
732
774
789
792
808
824
885
886
901
953
954
981
983
PARTNAME
O-RING
O-RING
OIL SEAL
BACKUP RING
BACKUP RING
NUT
STOP RING
VALVE PLATE PIN
SPRING PIN
EYE BOLT
SET SCREW
SET SCREW
NAME PLATE
PIN
QTY
4
2
1
2
2
4
2
2
4
2
2
2
1
2
Issued 03-07
Copyright
8030-6
Internal structure drawing of PTO
Description
No.
115
117
118
125
126
128
262
326
435
468
710
728
825
826
827
886
PART NAME
IDLER SHAFT
GEAR 2ND
GEAR 3RD
BALL BEARING
ROLLER BEARING
BEARING SPACER
COVER
GEAR CASE
PLUG
O-RING
O-RING
SNAP RING
SNAP RING
SNAP RING
PIN
Lep SC4608030-0EN
QTY.
1
1
1
2
1
2
1
1
8
1
1
1
1
1
1
2
Issued 03-07
Copyright
8030-7
CONTROL VALVE
Operation
1. Operation with all spools in neutral position

1) Neutral passage (Figures 1 and 2)
Oil supplied from Port P1 enters the tank passage Ta from neutral passage L1, passing the restriction Lc1
on the low pressure relief, and returns to Ports T1, T2, T3, T4 and T5.
Oil supplied from Port P2 passes the tank passage Ta through neutral passage R1, passing the restriction
Rc1 on the low pressure relief, and returns to Ports T1, T2, T3, T4 and T5.
Pressures in the pressure chambers L2 and R2 located in the upstream of the low pressure relief valve
are directed to the pump through Ports ps1 and ps2 and control the delivery volumes of pumps P1 and
P2.
In addition, if a large amount of extra oil flows into the neutral passage, the low pressure relief mechanism
functions to prevent pressures on Ports ps1 and ps2 from increasing abnormally.
2) Regulator operation explanation diagram

Oil supplied from port PP goes into port PT through throttle [Lc3]. It also flows into the tank passage [Ta]
through the land [Rc3], passing through the land [Lc4] and passage (5).
Part of the oil supplied from port PP goes into port PA through throttle [Lc5]. It also flows into the tank
passage [Ta] through the boom 1 spool land [Rc4], passing the passages [L4], (8) and [R4].
The oil that has passed through throttle [Lc6] flows into the tank passage [Ta] through the land [Lc7]. It
also passes through passage (4) and flows into the tank passage [Ta] through the travel spool land [Rc5].
[fig. 1]
NTROL VALVE
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-8
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-9
Single operation
1. Travel spool switching (Figures 3 and 4)

When switching the travel spool by adding pressure through the pilot port Pb1 (Pa1) in travel (Section 1),
the oil supplied from port P1 flows into port B1 (A1) passing through the neck part of the spool via neutral
passage [L1]. The returning oil passes through the neck part of the spool via port A1 (B1) and returns to
the tank passage [Ta]. When switching the travel spool by adding pressure through pilot port Pb6 (Pa6) in
travel (Section 6), the oil supplied from port P2 flows into port B6 (A6) passing through the neck part of
the spool or passage [S6-1] via neutral passage [R1]. At this moment, because pressures on parallel
passages [R3] and [S6-1] are equal, the poppet [S6-2] does not open. The returning oil passes through
the neck part of the spool via port A6 (B6) and returns to the tank passage [Ta]. When switching only one
side of the spool in travel (Section 1 or 6), land [Lc4] or [Rc3] closes. Since the flow of oil supplied from
port PP to the tank passage is shut off, the pressure on port PT increases.
fig.3
fig.4
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-10
2. Swing spool switching [Fig. 5]

When switching the swing spool by adding pressure through pilot port Pb2 (Pa2) in swing (Section 2), the
neutral passage [L1] closes. Oil supplied from port P1 passes from parallel passage [L3] through load
check valve [S2-1], passage [S2-2] and the neck part of the spool and flows into port B2 (A2). The
returning oil passes through the neck part of the spool via port A2 (B2) and returns to the tank passage
[Ta].
fig.5
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-11
3. Boom spool switching

1) Neutral Position [Fig. 6]
This valve has an anti-drift valve installed on the cylinder bottom side of boom 1. In the neutral position,
the poppet [AD1] is firmly seated by the pressure on port A7 that is directed to the spring chamber [AD5]
through the passage [AD2], spool [AD3] and passage [AD4].
2) Boom-up (2-pump confluence) [Fig. 7]

When switching the boom 1 spool by adding pressure through pilot port Pa7 in boom 1 (Section 7), the
neutral passage [R1] closes. Oil supplied from port P2 passes through the parallel passage [R3], the load
check valve [S7-1] and the neck part of the spool and flows into port A7. When switching the boom 2 spool
by also adding pressure through pilot port Pa3 in boom 2 (Section 3), the neutral passage [L1] closes. Oil
supplied from port P1 passes through the parallel passage [L3], the load check valve [S3-1], the neck part
of the spool and passage (6), and merges and flows into port A7. The returning oil passes through the
neck part of the spool via port B7 and returns to the tank passage [Ta].
3) Boom-down (regeneration) [Fig. 8]

When switching the boom 1 spool by adding pressure through pilot port Pb7 in boom 1 (Section 7), the
neutral passage [R1] closes. Oil supplied from port P2 passes through the parallel passage [R3], the load
check valve [S7-1] and the neck part of the spool and flows into port B7. When switching the spool [AD3]
in the anti-drift valve by adding pressure to port pc2 and reducing the pressure in spring chamber [AD5] at
the same time, the poppet [AD1] opens and the returning oil from port A7 returns to tank passage [Ta].
Part of the returning oil pushes open the poppet [S7-3] in boom 1 spool, passes through the passage [S72] and merges into port B7 to prevent cavitation on the cylinder rod side.
fig.6
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-12
fig.7
fig.8
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-13
4. Backup spool switching [Fig. 9]

When switching the backup spool by adding pressure through pilot port Pb4 (Pa4) in backup (Section 4),
the neutral passage [L1] closes. Oil supplied from port P1 passes through the load check valve [S4-1], the
passage [S4-2] and the neck part of the spool through the parallel passage [L3] and flows into port B4
(A4). When switching the neutral cut spool [R] at the same time by adding pressure through port Pa
(Fig. 1), the oil supplied from port P2 passes through passage (11) and poppet [S4-3] to merge and flow
into passage [S4-2]. The returning oil passes through the neck part of the spool via port A4 (B4) and
returns to the tank passage [Ta].
5. Bucket spool switching [Fig. 10]

When switching the bucket spool by adding pressure through pilot port Pb8 (Pa8) in bucket (Section 8),
the neutral passage [R1] closes. Oil supplied from port P2 passes through the load check valve [S8-1], the
passage [S8-2] and the neck part of the spool through the parallel passage [R3] and flows into port B8
(A8). The returning oil passes through the neck part of the spool via port A8 (B8) and returns to the tank
passage [Ta].
fig.9
fig.10
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-14
6. Arm spool switching

1) Dump (2-pump confluence) [Fig. 11]
When switching the arm 1 spool by adding pressure through pilot port Pb5 in arm 1 (Section 5), the oil
supplied from port P1 flows into port B5 passing through the load check valve [S5-1], the passage [S5-2]
and the neck part of the spool via the neutral passage [L1]. When switching the arm 2 spool by also
adding pressure through pilot port Pb9 in arm 2 (Section 9), the oil supplied from port P2 passes through
the load check valve [S9-1], the passage [S9-2], the neck part of the spool and passage (10) via the
neutral passage [R1] to merge and flow into port B5. The returning oil passes through the neck part of the
spool via port A5 and returns to the tank passage [Ta].
fig.11
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-15
2) Crowd (2-pump confluence) [Fig. 12]

When switching the arm 1 spool by adding pressure through pilot port Pa5 in arm 1 (Section 5), the oil
supplied from port P1 flows into port A5 passing through the load check valve [S5-1], the passage [S5-2]
and the neck part of the spool via the neutral passage [L1]. When switching the arm 2 spool by also
adding pressure through pilot port Pa9 in arm 2 (Section 9), the oil supplied from port P2 passes through
the load check valve [S9-1], the passage [S9-2], the neck part of the spool and passage (9) via the neutral
passage [R1] to merge and flow into port A5. When switching the spool [AD3] in the anti-drift valve by
adding pressure to port pc1 and reducing the pressure in the spring chamber [AD5] at the same time, the
poppet [AD1] opens and the returning oil from port B5 passes through the neck part of the spool, the
passage [S5-3] and the arm variable regenerative throttle [Lc8] to return to tank passage [Ta]. Part of the
returning oil pushes open the poppet [S5-4] in arm 1 spool, passes through the passage [S5-2] and
merges into port A5 to accelerate the cylinder speeds. It also prevents the cavitation on the bottom side.
3) Variable regeneration (during crowding) [Fig. 13]

During arm crowding, the spool [S5-6] strokes according to the pressure at the passage [S5-2], which was
directed through the passage [S5-5], so the opening of arm variable regenerative throttle [Lc8] changes
accordingly. If the pressure at the passage [S5-2] is high, the stroke of spool [S5-6] increases and the
opening of throttle [Lc8] becomes larger. On the other hand, if the pressure at the passage [S5-2] is low,
the stroke of spool [S5-6] decreases and the opening of throttle [Lc8] becomes smaller. Thus, the
regenerating flow varies according to the bottom pressure on the arm cylinder.
fig.12
Arm variable
regenerative
throttle
fig.13
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-16
7. Neutral cut spool switching [Fig. 14]

This valve has a neutral cut spool installed at the lowest stream of the neutral passage [R1] (at the upper
stream of the low-pressure relief valve).
When switching the neutral cut spool [R] by adding pressure to port Pa10, the neutral passage [R1]
closes.
Oil supplied from port P2 passes through passage (11), poppet [S4-3] (Fig. 10) and merges and flows into
passage [S4-2] in backup (Section 4).
8. Parallel throttle for arm [Fig. 14]

This valves parallel circuit for the arm has throttle valves installed in both arm 1 (Section 5) and arm 2
(Section 9). Consequently, the arm speeds are kept from slowing down even in combined operations.
The parallel circuit in arm 2 (Section 9) is connected with the passage [S9-2] (Fig. 12) after being
restricted by throttle [Rc6] at the end of poppet [S9-3] through parallel passage [R3].
The parallel circuit in arm 1 (Section 5) pushes open the poppet [S5-8] through parallel passage [L3] and
is connected with passage [S5-2] (Fig. 12) after being restricted by throttle [Lc9] in the parallel variable
throttle spool. The degree of restriction for throttle [Lc9] can be changed by adding pressure onto pilot
ports Pc4 and Pc5.
Arm parallel variable throttle
Arm parallel throttle

Neutral cut spool
fig.14
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-17
9. Relief valve
1) Main relief valve (Fig. 15)
Oil supplied from port P1 passes through the poppet [LP], and oil supplied from port P2 passes through
the poppet [RP] and passage (3). The two flows of oil are thus directed to the main relief valve. The
operation of the main relief valve regulates the maximum pressure on the P1 and P2 sides of the pump.
2) Overload relief valve

In each cylinder port of boom 1, arm 1 and bucket, an overload relief valve is installed to prevent an
abnormal boost of pressure on the actuator due to external force.
This relief valve also prevents cavitations by drawing oil in from the tank when pressure on the cylinder
port becomes negative.
fig.15
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-18
Combined Operations
1. Added operation with travel (Fig. 16)

If a task other than travel takes place during travel right/travel left movement (during forward/reverse or
pivot turning), or if travel right/travel left movement takes place while a task other than travel is being
performed, the oil supplied from port PP is shut off from the tank passage [Ta] at the signal land section
(other than travel) which has switched over to lands [Lc4], [Lc7], [Rc3] and [Rc5]. As the result, the
pressure in the signal passage will rise up to the set relief pressure, which is the source of oil pressure for
signals. A rise in signal pressure switches the straight travel spool. The pressures on port PT and PA also
increase. Once the straight travel spool is switched over, oil supplied from port P1 flows from the neutral
passage [L1] into travel (Section 1). It also passes through passage (2), the neck part of the straight travel
spool and neutral passage [R1] and flows into travel (Section 6). Oil supplied from port P2 passes through
the neck part of the straight travel spool and passage (1) and flows into the parallel passage [L3]. If the
negative pressure on sections other than travel is higher than the negative pressure on travel (Section 6),
part of oil supplied from port P2 pushes open the poppet [S6-2] and passes through the throttle at the end
of the poppet and merges in passage [S6-1]. Since travels (Sections 1 and 6) are achieved with oil
supplied from port P1 and tasks other than travel are achieved with oil supplied from port 2, the straight
travel is maintained during combined operation during travel right/left movement or combined operation
with other machines.
fig.16
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-19
Anti-drift Valve
This anti-drift valve is attached on the cylinder port of the arm rod (bottom side of boom) to prevent a
natural drop of the arm (boom) cylinder.
In neutral (Fig. 17), pressure on the cylinder port passes through the neck of spool [AD3] via passage
[AD2] and is directed to the spring chamber [AD5] through passage [AD4].
The force of the spring and the pressure differential in the poppet areas firmly seats poppet [AD1].
During arm dump (boom-up) (Fig. 18), oil supplied from the pump pushes open the poppet [AD1] and
flows into the cylinder port.
During arm crowding (boom-down) (Fig. 19), pressure is applied to pc1 (pc2) to switch over spool [AD3],
directing oil from the spring chamber [AD5] into the drain port DR1 (DR2) via passage [AD6] to open the
poppet [AD1]. As a result, oil returning from the cylinder port flows into the tank passage [Ta].
fig.17
AD3 (With spool switched over)
fig.18
fig.19
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-20
Relief Valve
1. Operation of the main relief valve

[1] This relief valve is integrated between the
neutral passage HP and low pressure passage LP, and oil passes the orifice in the
poppet (C) and fills the internal space (D).
The sleeve (E) and main poppet (C) act on
different areas (A and B). They are firmly
seated.
[2] If the pressure in the neutral passage HP

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

pressure in (D) reduces and the main poppet
(C) opens. As a result, the oil flows directly
into the passage LP.
Boost operation
When applying pressure to the pilot port PH,
the piston (H) moves to the set position by
plug (I). Due to this, the pilot spring force rises and the pressure in HP rises.
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-21
2. Operation of the overload relief valve

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

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

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

backside of the poppet (D) is only through
the poppet (D), annular space in the piston
(C) and the orifice (F). As a result, the differential pressure increases. Due to this, the
poppet (D) opens, and the oil flows directly
into the passage LP.
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-22
3. Draw-in-oil feature of the overload relief valve
[1] This relief valve has an anti-void unit incorporated. This unit supplies oil to the cylinder
port HP when cavitation takes place.
When the pressure in the cylinder port HP
is lower than the low pressure side LP, the
differential pressure between (A) and (B)
opens the sleeve (K). As a result, oil enters
the cylinder port HP through the low pressure side LP and this prevents cavitation.
4. Function of low-pressure relief valve

[1] When oil doesn't flow
[2] Neutral spool

Oil from a neutral passage HP flows to a
flow low-pressure passage LP in signal
orifice A.
The pressure of the signal port 4Ps(5Ps)
goes up by signal orifice A.
[3] Function of low pressure relief

The poppet B opens, and when it becomes pressure set with spring C when
excessive oil flows to a neutral passage
HP, it flows directly to LP and oil from a
neutral passage HP prevents the abnormality pressure being generated.
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-23
SWING UNIT
Configuration of Components
Swash plate type axial piston motor
Mechanical brake
Makeup valve
Relief valve
Bypass valve
NOTE: Numbers in parentheses in the following text correspond to the circled numbers in the Internal structural
drawings.
Structure of Hydraulic Motor

The rotary component group is composed of a drive shaft integrated type cylinder [27] and nine piston
assembly [8] arranged in the cylinder [27]. Additionally, both ends of the cylinder [27] are supported with
bearings [4] and [25]. Piston assembly [8] are guided by return plates [6] and spring bearings [7] so that
they can slide on the cam plates [5] smoothly.
The balance plate [24] is pressed against the end face of cylinder [27] by the force of coned disc spring
[17] and hydraulic pressure acting on the bushing [15].
Mechanical brakes [9], [10], [11] and [14] that are used as parking brakes are installed between the
circumference of cylinder [27] and the housing [28].
Also, a relief valve [31] as cushion and makeup valves [35], [36] and [39] for preventing cavitation are built
in the cover section [29]. In order to prevent swinging-back when swing operation is stopped, a bypass
valve [43] is integrated into the cover [29].
Operational Description of Hydraulic Motor

Hydraulic oil supplied from the pump via the control and other valves enters from port A (or port B) on the
cover [29] and is discharged from port B (or port A). Oil leaked from gaps in each sliding part is returned
to the tank through the drain port "a" on the cover [29].
The pressurized oil supplied to port A is supplied to the piston hole "f" in the cylinder [27], passing the
following components in order: passage "b" in the cover [29], passage "c" on the bushing [15] section on
the cover [29], passage "d" on the balance plate [24] which has a crescent-shaped port switching between
supply and discharge every 180 per one motor turn, as well as, passage "e" on the cylinder [27].
The oil pressure acts on piston assembly [8], resulting in piston assembly [8] being pressed to the cam
plate [5] via the shoe section. Because the sliding face of the shoe on cam plate [5] is inclined at a given
angle, the pressing force on the piston assembly [8] to which the oil pressure pushes, is transformed into
a force that slides the shoe on the swash plate. Because the spherical shoe section of piston assembly [8]
is connected so that it works as a universal joint, the shoe's sliding force on the swash plate is transferred
to the motor output shaft as a turning force via the piston assembly [8] and cylinder assembly [27].
As mentioned above, each piston assembly [8] receives the pressurized oil while it travels the stroke from
the top dead center to the bottom dead center of the incline plane and transforms it into a turning force to
revolve cylinder assembly [27] and discharges oil while it travels the stroke from the bottom dead center to
the top dead center. The discharge route is the reverse of the supply route described above and the oil is
discharged from port B.
The hydraulic motor operates in the manner as described above. Its output torque and the number of
revolutions are determined according to the hydraulic force and the volume of oil supplied respectively.
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-24
Operational Description of Mechanical Brake

Friction plate [9] is connected to the circumference of cylinder assembly [27] via spline. Also, the
counterpart plate [10] is connected to the housing [28]. When the pressure in the mechanical brake
release chamber is zero, the cylinder assembly [27] (output shaft) is locked and will not turn as a result of
the brake piston [11] pressing the counterpart plate [10] and friction plate [9] through the spring force [14].
In the opposite manner, when the oil pressure of 2.9 to 4.9 MPa is reached on the brake release chamber,
the brake piston [11] overcomes the force and moves until it hits the end face of the cover [29], creating
space between friction plate [9] and counterpart plate [10]. As a result, the mechanical brake turns to a
released status.
Operational Description of Make-up Valve
1. Half-braking condition (a state where relief valve [31] is not in operation)

When decelerating the swing body through the control valve using the half-lever function after
accelerating the swing body, the supply volume to port A from the pump decreases but it is necessary to
supplement oil when the swing body is rotating at a relatively high speed because the pressure applied to
the "c" section tends to become negative due to motor's pumping action.
However, because the whole volume of oil which flows into "c" section from port A is discharged into
control valve via port B when the pressure on port B is lower than the working pressure of relief valve [31],
the absolutely necessary oil volume at the "c" section is not met with the oil volume from the control valve
alone (as the valve is in the half-lever position, the oil volume is still restricted). To prevent this, makeup
check [39] is provided to supplement "c" section to make up for a lack of oil through the makeup port.
2. Full braking condition (a state where relief valve [31] is in operation)

When changing to the neutral position from condition A by quick lever operation, the swing body is turned
by inertial force even though the oil supply volume from the pump to port A becomes zero. In this case,
relief valve [31] on the port B side operates, and the oil, which blew off the relief, passes oil passages "g"
and "h", presses open the makeup check [39] on port A and is supplemented to the passages "b" and "c".
However, the oil lacks by its volume that which has leaked into the case drain of the motor. To prevent this,
the makeup check [39] is opened from the makeup port and the oil flows into the passages "b" and "c" in
order to prevent cavitation.
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-25
Operational Description of Relief Valve

(Internal structural drawing of relief valve)
1. When starting
The hydraulic oil supplied from port A by operating the control valve does not immediately reach the
constant revolution level due to the large inertial force of the swing body. Part of the oil passes oil
passages "g" and "h" via relief valve [31] that works as a safety valve, presses open the check [39] on port
B side and flows into port B.
Oil in port A presses open the poppet [47] by counteracting the force of spring [48], passes passage "g"
via a space between seat [46] and poppet [47] and flows into passage "h".
2. When braking (at time of cushioning)

When the control valve is returned to the neutral position, the return passage for the motor's drain oil
closes. Immediately after this operation, the motor is turned by large inertial force and attempts to suck oil
through port A by pumping action and to discharge it to port B. As a result, the pressure on port B
increases because the return passage in the control valve is closed.
As the increased pressure on port B presses open poppet [47] by counteracting the force of spring [48],
the oil flows into passage "c" by pressing open the makeup check [39] via oil passages "g" and "h" through
port B. In this process, the inertial force of the swing body is absorbed and the swing body comes to a
stop.
Also, in the pressure increasing process above mentioned, the highly pressurized oil that flowed into the
front chamber of poppet [47] enters the piston chamber passing the small hole passage on the central
section of piston [52] via circumferential orifice "j" of poppet [47] and moves piston [52] until it hits the end
face of sleeve [51]. Meanwhile, since poppet [47] is already forcedly opened, the cushion relief begins to
work at relatively low pressure, and then increases to a specified pressure in minimal time. This dual-step
action decreases the impact of motor starts and stops.
Operational Description of Bypass Valve

(Internal structural drawing of bypass valve)
When attempting to stop the swing body after operating the control valve to drive the swing body, braking
pressure is generated on one side of the port as the hydraulic motor, which keeps rotating due to its
inertial force, continues its pumping action.
Suppose that this is port A: This pressurized oil for braking flows into the back chamber of check [60] on
the side A via small holes [a3] and [a2]. As a result, the check [60] on side A moves until it contacts and
presses seat [58] on side A to shut off the bypass passage by pushing check [60] on side B, which is
arranged as a counterpart, to the left in the process of decelerating the swing body. In due course, the
swing body stops once but reverses due to braking pressure. Therefore, the pressure on side B increases
and check [60] on side B attempts to move to the right by pushing check [60] on side A, which is arranged
as a counterpart. However, this movement of check [60] is a little delayed because the oil flow of the back
chamber in check [60] on side A is gently controlled through the action of the flow control valve comprised
of poppet [61] on side A and spring [62] on side A. In the meantime, the pressurized oil of port B flows into
the intermediate chamber via small hole "b1" and bypasses port A side via small hole "a1". Subsequently,
check [60] on side B contacts and presses seat [58] on side B and moves to the position where it can shut
off the bypass passage. As described above, the reverse motion will be prevented without any trapping of
the oil because the pressure is bypassed to port A side in the process of generating reverse pressure on
the port B side.
Lep SC4608030-0EN
Issued 03-07
Lep SC4608030-0EN
28
27
25
10
24
11
23
12
Mechanical brake release chamber
26
22
13
21
20
19
18
17
16
15
14
41
40
Port B
42
39
38
37
Top dead
center
35
43
Port A
33
34
32
36
Bottom
dead center
Relief on port A side
Relief on port B side
44
34
45
Makeup port
Drain port
29
30
31
Copyright
8030-26
Internal Structural Drawing
Issued 03-07
Copyright
8030-27
Internal Structural Drawing of Externally Adjusted Shockless Relief Valve

46
47
48
49
50
51
52
53
57
56
55
54
Internal Structural Drawing of Bypass Valve

58
59
Port B
b3
Lep SC4608030-0EN
60
61
62
Port A
b2
b1
a1
a2
a3
Issued 03-07
Copyright
8030-28
TRAVEL UNIT
Structure
Fig.1. Structure drawing of travel motor

SYM
PART NAME
CASING
NPT1/16 PLUG
OIL SEAL
RETAINING RING IRTW68
SHIFTER PISTON
PISTON SEAL
STEEL BALL
SHAFT
BEARING HR33209J
10
PIVOT
11
SWASH PLATE
12
CYLINDER BLOCK
13
CYLINDER SPRING
14
SPRING HOLDER
15
BALL JOINT
16
SHOE RETAINER
17
PISTON ASSY
18
SEPARATING PLATE
19
FRICTION PLATE
20
BRAKE PISTON
SYM
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
PART NAME
D-RING (SMALL DIA.)
D-RING (BIG DIA.)
REAR COVER
NPT1/16 PLUG (MEC)
SPOOL ASSY
SPRING HOLDER
SPRING
M42 PLUG
O-RING 1B G40
PILOT VALVE SPOOL
PIN
SPRING HOLDER
SPRING
G3/8 PILOT VALVE PLUG
O-RING 1B P14
CONNECTOR
G1/4 PLUG
O-RING 1B P11
RESTRICTOR (BRAKE VALVE)
RESTRICTOR SPRING (BRAKE
VALVE)
SYM
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
PART NAME
G1/8 PLUG
O-RING 1B P8
CHECK VALVE
CHECK VALVE SPRING
M6 RESTRICTOR (0.6)
O-RING 1B P12.5
M6 RESTRICTOR (0.8)
O-RING 1B P15
O-RING 215.57 X 2.62
BEARING HR32207C
SHIM
PARALLEL PIN
VALVE PLATE
BRAKE SPRING
HEX. SOCKET HEAD BOLT M18 X 50
COUPLING
RETAINING RING C-TYPE 40
G1/2 PLUG
O-RING 1B P18
Table 1. Parts list of travel motor
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-29
Brief Explanation of Structure

The motor mainly consists of the following parts:
Rotary group producing turning force to drive shaft
Parking brake preventing host machine from self-running during its rest
Capacity control parts that changes the motor capacity consequently rotating speed
Overload relief valve that is attached to the rear cover
Brake valve (counter balance valve) portion that control the hydraulic circuit
1) Rotary Group
The cylinder block [12] is inserted into the spline of shaft [8], both ends of which are supported by
bearings [9], [50]. This cylinder block [12] is pushed toward the rear cover [23] together with valve plate
[53] by cylinder spring [13].
Nine pieces of piston assy [17] slide inside the cylinder block [12] along the surface of swash plate [11].
Hydrostatic bearings are provided on the end surface of piston assy [17] to reduce the sliding resistance,
and the ends of piston ass'y [17] are pushed toward swash plate [11] by cylinder spring [13] through
spring holder [14], ball joint [15] and shoe retainer [16].
2) Parking brake
Seven pieces of separating plates [18] and six pieces of friction plates [19] are alternately set on the
spline of cylinder block [12] and pushed together by 14 brake springs [54] through brake piston [20].
3) Capacity control portion

They consist of: pivots [10] that support swash plate [11] and slide in two half-spherical recesses in swash
plate [11] : shifter piston [5] that change the angle of swash plate [11] on the pivots [10] : stopper [1-1] of
casing that limits the angle of swash plate [11] : pilot valve portion that leads the oil to shifter piston [5] by
external pilot signal : three check valves [43] that select the maximum pressure from the external pilot
pressure, inlet pressure and outlet pressure of the motor and send it to pilot valve portion.
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-30
4) Overload relief valve

This valve is screwed in the motor rear cover [23] and consists of : socket [56-1] that is screwed and fixed
in the rear cover [23] and supports the valve seat [56-3] which metallically seated in the hole of rear cover
[23] : valve [56-2] that contact with valve seat [56-3] by adjusting spring [56-9] and fitted in the hole of
socket [56-1] : coupling piston [56-4] that fitted in the hole of the valve [56-2] and functions also as an oil
passage : piston [56-7] that is inserted in the pilot body [56-6] and : shim [56-8] that adjust the spring
force.
Fig.2. Structure drawing of overload relief valve
SYM
PART NAME
SYM
PART NAME
56-1
SOCKET
56-8
SHIM
56-2
VALVE
56-9
ADJUSTING SPRING
56-3
VALVE SEAT
56-10
O-RING 1B P7
56-4
COUPLING PISTON
56-11
BACK-UP RING T2 P7
56-5
CAP
56-12
O-RING 1B G25
56-6
PILOT BODY
56-13
BACK-UP RING T2 G25
56-7
PISTON
Table 2. Parts list of overload relief valve
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-31
5) Brake valve portion

Spool control pressure : 0.59 to 0.95 MPa
Check valve cracking pressure : 0.015 MPa
Fig.3. Brake valve portion

The brake valve portion mainly consists of the following parts:
1] Spool
By shifting the spool [25], the discharged oil from hydraulic motor is automatically shut off or restricted
according to the condition and give the effect of holding, accelerating, stopping and counterbalance
operations.
2] Check valve (Built in the spool)
This valve is located in the oil supplying passage to hydraulic motor, and at the same time functions to
lock oil displacement. Therefore, this valve serves as not only a suction valve but also a holding valve for
hydraulic motor.
Lep SC4608030-0EN
Issued 03-07
Copyright
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Function
Direction of rotation (Viewing
Inlet
port
Outlet
port
VB
VA
Right (Clockwise)
VA
VB
Left (Counterclockwise)
from rear cover)
Table 3. Direction of rotation
Fig.4. Lacation parts
1. Operation of motor
High pressure oil delivered from hydraulic pump is led to inlet port(VA,VB) that is provided in the brake
valve portion and, through the rear cover [23] and valve plate [53], led to cylinder block [12].
The oil flow and direction of shaft rotation are indicated in Table 3.
Fig.5. (a)
Fig.5. (b)
As shown in Fig.5(a), high pressure oil is supplied to the pistons which are on one side of the line Y-Y that
connects upper and lower dead points and produces force F1
F1 = P x A (P : pressure, A : area of piston section)

The swash plate [11] with inclined angle of divides this force F1 into thrust force F2 and radial force F31F34 (or F35). (Fig.5 (b)) This radial force is applied to axis Y-Y as turning force and generate drive torque
of T
T=r1 F31 + r2 F32 + r3 F33 + r4 F34

(In case high pressure oil is applied to five pieces of pistons, r5 F35 should be added.)
This drive torque is transmitted via cylinder block [12] to driving shaft [8].
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-33
2. Operation of parking brake

Parking brake is released when high pressure oil, selected by the brake valve portion that is connected
directly to the rear cover [23], is applied to the brake piston [20].
Otherwise the braking torque is always applied.
This braking torque is generated by the friction between the separating plates [18], inserted into the
casing [1], and friction plates [19], coupled to cylinder block [12] by the outer splines.
When no pressure is activated on the brake piston [20], it is pushed by the brake springs [54] and it
pushes friction plates [19] and separating plates [18] towards casing [1] and generates the friction force
which brakes the rotation of cylinder block [12] and hence the shaft [8].
Fig.6. Parking brake portion
Lep SC4608030-0EN
Issued 03-07
Copyright
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3. Operation of capacity variable mechanism
Fig.7. Operation of capacity variable mechanism

Fig.7 typically shows the capacity variable mechanism.
When high speed pilot line is charged with the pressure PA that overcome the spring [33], the spring [33]
is compressed and spool [30] shifts to the right to connect the port P and port C.
Then, the highest pressure is selected by the check valve [43] from inlet and outlet pressure of the motor
and high speed pilot line pressure and pushes shifter piston [5]. As a result, swash plate [11] turns around
the line L which connect the two pivots [10] as shown by dotted lines. The turn stops at the stopper [1-1]
of casing and swash plate [11] keeps the position.
In this case, the piston stroke become shorter and motor capacity become smaller and motor rotates
faster, around 1.71 times, by the same volume of oil.
When no pressure is in the high speed pilot line PA , spool [30] is pushed back by the spring [33] and
pressure that pressed the shifter piston [5] is released to the hydraulic tank through restrictor [45].
Here, nine pistons are there and they equally spaced on the swash plate [11]. The force that summed up
those of pistons comes to almost the center of the swash plate [11] as shown. Since the pivots [10] are
off-set by S from the center, the rotating force of product S and the force moves swash plate [11] to the
former position and the speed returns to low.
When the power demand exceeds the engine power, such as in steep slope climbing or turning at high
speed mode, the system step down to the low speed automatically. The mechanism is that: pump
pressure (VA or VB) is led to the port PB [Fig.7]. and this pressure activate on pin [31]. When the pressure
at PB exceeds predetermined value, spool [30] returns to the left by the counter-pressure against pin [31]
and the pressure on the shifter piston [5] through port C is released to the tank and the motor comes to
low speed.
When PB goes down, the spool [30] moves to the right and the speed become high.
Lep SC4608030-0EN
Issued 03-07
Copyright
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4. Operation of overload relief valve

Two pieces of overload valves are located at cross-over position in the counterbalance circuit of brake
valve and have the following functions:
1] When hydraulic motor starts, keep the driving pressure below predetermined value and while
accelerating, bypasses surplus oil to return line.
2] When stopping the motor, keep the brake pressure, that develops on the outlet side of motor, under
the predetermined value to stop the inertial force.
3] To accelerate sharply while starting, and to mitigate the braking shock while stopping. For these
purposes, the developed pressure is kept comparatively low for a short period, then keep the line
pressure as normal value. While the pressure is low, meshing of reduction gears, crawler and sprocket
etc. can be smoothly done and the shock are absorbed.
When starting, "A" port pressure of overload valve increases, this pressure is applied to the effective
diameter of valve [56-2] which seats on the valve seat [56-3] and, at the same time, is delivered, via small
hole, to the connecting piston [56-4] located inside the valve [56-2] and the piston bore pressure
increases up to "A" port pressure. The valve [56-2] opposes to adjusting spring [56-9] by the force of the
pressure exerted on the area difference between valve seat's effective diameter and piston bore and keep
the predetermined pressure.
When hydraulically braking, the piston [56-7] is at the left position by the driving pressure, and when "A"
port pressure increases, the pressure is applied also to the piston [56-7] through the small hole in the
valve [56-2] and connecting piston [56-4] moves rightward until it touches the cap [56-5]. In this while, the
valve [56-2] maintains "A" port pressure at comparatively low against the adjusting spring [56-9] force and
exhaust oil to "B" port side. After the piston reached to the plug, the valve acts the same as at starting.
Fig.8. Operation of overload relief valve
Lep SC4608030-0EN
Issued 03-07
Copyright
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5. Operation of brake valve

1) Holding status (see Fig.9)
When the control valve is at neutral position, VA and VB ports are connected to the tank, and the spring
[27] located on both spool ends holds the spool [25] at central position.
Therefore, the passages from VA to MA and VB to MB are closed, which result in closing MA and MB
ports connected to hydraulic motor.
Since the passage to parking brake is connected to the tank line, the brake cylinder pressure is equal to
the tank pressure and the brake is applied by the springs. Thus, the rotation of the motor is mechanically
prevented.
If external torque is exerted on the motor shaft, the motor would not rotate as usual by this negative
parking brake.
In case the brake should be released for some reason, pressure is built on MA or MB port. But, due to oil
leakage inside hydraulic motor or so, high-pressure oil escapes from the closed circuit and motor rotates
a bit. So, the cavitation tends to occur in the lower pressure side of the closed circuit. Then, the check
valve, built in the spool [25], operates to avoid the cavitation and opens the passage from VA to MA or
from VB to MB. Then the oil equivalent to the leakage is sucked from the tank line to the closed circuit.
Spring
Spring
Fig.9. Holding status
Lep SC4608030-0EN
Issued 03-07
Copyright
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2) Accelerating operation (see Fig.10)

When VA and VB ports are connected respectively to pump and tank by operating the control valve,
hydraulic oil from pump is forwarded through VA port to push open the check valve provided inside spool
[25], and oil flows to motor via MA port to rotate the motor.
Therefore, the pressure increases and negative brake is released by the pressure supplied from pump. At
the same time, the pressure of pilot chamber increases to push and move the spool [25] leftwards,
overcoming the spring [27] force. Thus, the return line from MB to VB opens to rotate the motor.
In case inertia load is too big to start rotation, accelerating pressure reaches the set pressure of relief
valve and high pressure oil is being relieved while the motor gains the rotational speed. As the rotational
speed goes up. the relieved volume decreases, and finally the motor rotates at a fixed speed.
Check valve
with restrictor
Pilot chamber
Check valve
with restrictor
Pilot chamber
Spring
Spring
Fig.10. Accelerating operation
Lep SC4608030-0EN
Issued 03-07
Copyright
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3) Stopping operation (see Fig.11)

Returning the control valve to neutral position while running the motor, the oil supply is cut off and VA and
VB ports are connected to the tank line. Then the pressure of the pilot chamber located on both spool
ends become equal, and the spool [25] returns to the neutral position by spring [27] force. Thus, the
passage from MA to VA is closed.
Owing to the inertia force of the load, the hydraulic motor tends to continue the rotation. Here, the motor
functions as a pump and forwards the oil to MB port but the passage is blocked and MB port pressure
increases. Then the relief valve opens to relieve the pressure and rotational speed decelerates and at last
the motor stops.
Negative brake release pressure is gradually lowered due to the restrictor and finally the brake works and
the motor is mechanically stopped.
Pilot chamber
Pilot chamber
Spring
Spring
Fig.11. Stopping operation
Lep SC4608030-0EN
Issued 03-07
Copyright
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4) Counterbalance operation (see Fig.12)

Counterbalance operation is required to decelerate slowly the hydraulic motor while absorbing inertia
force.
In case the hydraulic oil is gradually decreased from pump to VB port, the drive shaft of hydraulic motor
tends to rotate faster than that matched to the volume of oil supply.
Consequently, the pilot chamber pressure on MB to VB side decreases and the spring [27] force moves
the spool [25] leftwards towards neutral position.
Therefore, the area of passage from MA to VA becomes smaller and the pressure on MA side rises due to
increased resistance in the passage and the motor receives hydraulic braking effect.
If the motor rotates slower than that matched to the volume of supplied oil, the pilot chamber pressure on
VB port increases, and spool [25] moves rightwards to enlarge the area of passage from MA to VA.
Therefore the braking effect becomes smaller and the rotational speed of motor is controlled to
correspond to the volume of supplied oil.
In order to give stable counterbalance operation, the restrictors [39] are set in the pilot chamber to damp
the spool [25] movement.
The parking brake is released during pressure adjusting action of the spool [25].
Check valve
with restrictor
Pilot chamber
Check valve
with restrictor
Pilot chamber
Spring
Spring
Fig.12. Counterbalance operation
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-40
FAN MOTOR FOR HYDRAULIC DRIVE

Outside Drawing
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-41
Internal Structure Drawing
No.
Lep SC4608030-0EN
Part Name
Output shaft
Case
Thrust plate
Piston assembly
Cylinder block
Valve plate
Retainer guide
Retainer shoe
Main bearing
10
Sub bearing
11
Oil seal
12
End cover
13
Center spring
14
Spring for suction safety valve
15
Suction safety valve
16
Variable flow control pilot valve
17
Flow control spool
18
Flow control spool spring
19
Main spool
20
Proportional solenoid
21
Filter
22
Forward/reverse changeover pilot valve
23
ON-OFF solenoid
Issued 03-07
Copyright
8030-42
Operation Principle
1. Hydraulic Motor
Function
The hydraulic motor is called as swash plate
axial piston motor and it converts force of pressure oil transferred from the hydraulic pump
into rotation.
Operation Principle
Oil flown out of the hydraulic pump is introduced into the cylinder block [5] through the
valve plate [7].
It has been so designed that the oil is to be introduced in the one side area of the line Y-Y
connecting the top dead center to the bottom
dead center in the piston [4] stroke.
Pressure oil entered in the one side part in the
cylinder block [5] pushes each piston [4] (2 pistons or 3 pistons) to generate force F1. (F1 N=P
MPa x /4 D2 cm2)
Although the force works to the thrust plate [2],
the force is divided to F2 and F3 as the thrust
plate [2] is fixed with a certain angle of
against the output shaft [1].
Of the component of a force, the radial force F3
generates each torque of (T=F3 x ri) against the
line Y-Y connecting the top dead center to the
bottom dead center.
The resultant force of the torque [T= (F3 x ri)]
allows the cylinder block [5] to be rotated via
piston as a turning force.
Since the cylinder block [5] makes a spline connection with the output shaft, the output shaft
rotates to transfer the torque.
Lep SC4608030-0EN
Issued 03-07
Copyright
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2. Suction Safety Valve (Safety Valve with Suction)

1) Function of Suction
Negative pressure in the inlet port of motor generates cavitation.
When pressure in the inlet port of the motor becomes negative, the suction valve has a function preventing cavitation from generating by supplying pressure oil from the outlet port.
2) Function of Safety Valve
Operation
[1] When starting
When pressure oil flown out of the pump
is supplied to the port P and pressure on
MA side increases to generate staring
torque in the motor, the motor starts rotation.
Oil on MB side of the outlet port of motor
will returns from port T to the tank.
[2] When stopping

When input speed of the fan pump gets to
0 min-1 due to engine stop, pressure oil
from the pump fails to be supplied to port
P.
Since pressure oil will not be flown in MA
side of the motor, the motor speed is being slowed down gradually to make it a
stop.
When motor shaft is rotated by inertia
with pressure oil flowing to port P being
decreased, pressure in the inlet port becomes negative.
In such case, the suction safety valve
prevents cavitation from being generated
by supplying pressure oil in port T on the
outlet side to Ma side.
Lep SC4608030-0EN
Issued 03-07
Copyright
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Function
Discharge pressure of the fan pump may
be raised in such case where the engine
is started.
In order to protect fan system circuit,
safety valve is installed.
When discharge pressure goes beyond
the pressure set at the safety valve, the
seat of safety valve opens to allow the oil
to be escaped into the passage to port T
to prevent unusual high pressure from
being generated.
Lep SC4608030-0EN
Issued 03-07
Copyright
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3. Variable Flow Control Valve

Function
It supplies oil discharged out of the pump to
the motor as necessary and allows surplus
oil to return to the tank.
The motor speed is increasing in proportion to
inflow quantity Q as illustrated in Fig. 1.
min-1 at inflow of Q1.
The pump rotates at
In order to aim at noise reduction and loss reduction as a function of fan motor, it is necessary to control fan speed for maintaining
necessary constant speed regardless of inflow.
A flow control valve is built-in as the function
meeting the requirements mentioned above.
Even when inflow increases from Q0 to Q1, motor speed keeps constant as
to
min-1 as illustrated in Fig.1
Operation
Basic operation of flow control is that pressure
difference in front and rear of the constriction
against the inflow works to the flow control
spring with constricted upstream pressure applied to side and constricted downstream pressure applied to
side of flow control spool.
In Fig. 1, if inflow surpasses Q0, pressure difference in front and rear of the flow control
spool becomes larger than load at mounting in
flow control spring.
This allows opening P to T to open and surplus
is discarded
flow in the section marked as
out of the flow control valve for which the motor
speed is to be kept constant in the range between
and .
The motor mounts electromagnetic proportional variable flow control valve.

The flow control valve of this type makes it
possible to change continuously the plateau between
and
as in Fig. 2 to constant speed of the motor in the range
between and altering the command
current.
Lep SC4608030-0EN
Issued 03-07
Copyright
8030-46
4. Operation of Forward / Reverse Changeover Valve

[1] When ON-OFF solenoid for changeover valve
is demagnetized
When ON-OFF solenoid for changeover valve
[1] is demagnetized, pressure oil from the
pump is shut off by ON-OFF changeover valve
[2] allowing port C to lead to the tank circuit.
This allows the changeover spool [3] to be
pushed to the right by the changeover spool
spring [4] and the motor port MA opens to let
the pressure oil flow in and as a result the motor makes forward rotation (CW).
Lep SC4608030-0EN
[2] When ON-OFF solenoid for changeover valve

is magnetized
When ON-OFF solenoid for changeover valve
[1] is magnetized, ON-OFF change over valve
[2] switches over and pressure oil from the
pump enters in the port C to let it flow into the
chamber D.
Pressure oil in the chamber D overcomes the
changeover spool spring [4] to push the
changeover spool [3] to the left.
This allows the motor port MB to open and
pressure oil flows in and as a result the motor
makes reverse rotation (C.C.W.).
Issued 03-07
9002
Copyright
Section
9002
UPPERSTRUCTURE, TURNTABLE
AND COUNTERWEIGHT
CNH
Lep SM4609002-0EN

Printed in France
September 2007
Copyright
9002-2
TABLE OF CONTENTS
SPECIAL TORQUE SETTINGS ..................................................................................................................................... 2
SPECIFICATIONS ......................................................................................................................................................... 2
UPPERSTRUCTURE .................................................................................................................................................... 3
Inspection ................................................................................................................................................................... 3
Removal ..................................................................................................................................................................... 4
Installation .................................................................................................................................................................. 6
COUNTERWEIGHT ..................................................................................................................................................... 10
Description ............................................................................................................................................................... 10
Removal .................................................................................................................................................................... 11
Installation ................................................................................................................................................................. 12

See Section 1002.
SPECIFICATIONS
Weight ................................................................................................................................................... See Section 1002
Lep SM4609002-0EN
Issued 09-07
Copyright
9002-3
UPPERSTRUCTURE
Inspection
STEP 1
STEP 5
Checking the turntable

If the upperstructure does not revolve properly or
creaks, this shows that the turntable is worn or damaged. If the upperstructure pauses before revolving,
this shows that the crown wheel of the turntable is damaged. When an operator is working with the machine,
he must pay attention to any unusual noises which
could indicate turntable wear. If the operator hears unusual noises and if the upperstructure pauses before
revolving, he must carry out the following inspection.
STEP 2
Park the machine on hard, level ground. Lower the
STEP 3
STEP 4
1
2
3
CS02C505
Remove the three screws (1) that fasten the access

door (2) to the machine. Remove the access door (2).
Remove and discard the seal (3) from the access door
(2).
STEP 6
1
CI00F500
Remove the screws (1) that attach the lower housing to

the machine and remove the lower housing.
WARNING: If your hand is in the access port of

the crown wheel when the upperstructure is
revolving, you could get seriously injured.
Before applying grease by hand on the crown
wheel, always check that the bucket or the tool
is placed on the ground and that the engine is
shut down.
Ask an assistant to help you operate the swing mechanism, check for scratches, missing teeth, scaling,
cracks or other damage on the crown wheel using a
pocket light. In case of damage, refer to "Removing the
upperstructure" and change the turntable of the upperstructure.
STEP 7
Install a new seal (3) on the access door and install the
access door (2) on the machine using screws (1).
Lep SM4609002-0EN
Issued 09-07
Copyright
9002-4
STEP 8
STEP 4
Install the lower housing on the machine using screws

and plate washers.
Removal
STEP 1
JS00163A1

STEP 2
STEP 3
1
2
FUEL TANK LOWER ACCESS PANEL

HYDRAULIC RESERVOIR LOWER ACCESS PANEL
Remove the lower access door of the fuel reservoir (1)

located in front and on the right. Place a container
beneath the drain valve of the fuel reservoir. Open the
drain valve and drain the fuel.
NOTE: See Section 1002 for the capacity of the fuel
reservoir.
STEP 5
Open the left-hand side door. Disconnect the earth
cable (1) from the battery. Close the LH side door.
Remove the lower access plate from the hydraulic reservoir (2). Place a container beneath the drain valve of
the hydraulic reservoir. Open the drain valve and drain
the hydraulic fluid into the container.
NOTE: See Section 1002 for the capacity of the
hydraulic reservoir and the capacity of the entire system.
STEP 6
Refer to Section 8006 and remove the hydraulic swivel.
Lep SM4609002-0EN
Issued 09-07
Copyright
9002-5
STEP 7
STEP 14
Refer to Section 9003 and remove the bucket, the dipper and the boom.
Remove the screws (3) that attach the turntable to the

undercarriage. Carefully disengage the turntable from
the undercarriage by lifting it. Place the turntable on
suitable supports in order to protect the surfaces of the
turntable from any damage. Remove the lifting equipment from the lifting rings and disassemble the lifting
rings from the turntable.
STEP 8
Refer to page 10 in this Section and remove the counterweight.
STEP 9
Install lifting rings at the rear of the upperstructure.
Connect a suitable lifting device to these lifting rings
and to the lifting rings located at the front of the upperstructure, above the boom brackets. Use the total
movement of the lifting device.
NOTE: Refer to specifications on page 2 for the weight
of the upperstructure. Make sure that the lifting equipment has sufficient lifting and support capacity for the
upperstructure.
STEP 10
4
CD01K066
Using paint or another marking product, make marks

on the upperstructure, turntable (4) and the undercarriage, to facilitate re-assembly of the upperstructure
and the turntable.
STEP 11
Remove the screws (1) as well as the flat washers (2)
of the upperstructure turntable (4).
STEP 12
Carefully disengage the upperstructure from the undercarriage by lifting it. Place the upperstructure on suitable supports in order to protect the swing reduction
gear pinion from any damage.
STEP 13
Install lifting rings on the turntable (4). Connect suitable
lifting equipment to the lifting rings. Use the total movement of the lifting device.
of the turntable.
Lep SM4609002-0EN
Issued 09-07
Copyright
9002-6
Installation
Turntable
2
1
2
4
2
1
3
CS02C506
1
2
3
4
SCREW
FLAT WASHER
SCREW
TURNTABLE
STEP 1
STEP 3
Clean the surfaces of the undercarriage and the turntable.
Position the turntable (4) on the undercarriage. Align

the marks on the turntable (4) and on the undercarriage. Remove the lifting equipment and remove the lifting rings from the turntable.

steps refer to the diagram of the turntable.
STEP 2
Install lifting rings on the turntable (4) and connect a
suitable lifting device to these rings. Use the total
movement of the lifting device.
of the turntable.
Lep SM4609002-0EN
Issued 09-07
Copyright
9002-7
STEP 4
STEP 10
Refer to Section 9003 and reassemble the boom, the
dipper and the bucket on the machine.
STEP 11
Make sure that the drain valve of the hydraulic reservoir
is closed. For filling the reservoir refer to the chapter
"Filling the reservoir" in the operators manual.
NOTE: See Section 1002 for the capacity of the

hydraulic reservoir and the capacity of entire system.
STEP 12
CD01K066
Coat the screw threads (3) with Loctite 262. Install the
screws (3) to attach the turntable (4) to the undercarriage. Tighten the screws (3) to the torques specified on
page 2.
STEP 5
Connect a suitable lifting device to the lifting rings
located in front of the upperstructure, on top of the
boom brackets, as well as to the rings installed on the
upper frame behind the upperstructure.
of the upperstructure. Make sure that the lifting equipment has sufficient lifting and support capacity for the
upperstructure.
NOTE: When the upperstructure is lowered and
touches the turntable and the crown wheel, make sure
that the swing reduction gear pinion engages perfectly
with the teeth on the upperstructure crown wheel.
STEP 6
Carefully install the upperstructure in position on the
turntable. Align the marks on the upperstructure and on
the turntable. Check that the mounting ports of the
upperstructure are aligned with those of the turntable.
STEP 7
Coat the screw threads (1) with Loctite 262. Install the
screws (1) with flat washers (2) in the turntable and the
upperstructure to fasten the upperstructure en position.
Tighten the screws (1) to the torques specified on page
2.
STEP 8
1
2
FUEL TANK LOWER ACCESS PANEL

HYDRAULIC RESERVOIR LOWER ACCESS PANEL
Install the access door (2) under the hydraulic reservoir,

as well as the access door (1) under the fuel reservoir.
STEP 13
STEP 9
Make sure that the drain valves of the fuel and hydraulic reservoirs are closed, fill the reservoirs (see the
operators manual).
Refer to Section 8006 and reassemble the hydraulic

swivel.
NOTE: See Section 1002 for the capacity of the fuel

reservoir and the hydraulic reservoir.
Remove the lifting device then remove the lifting rings.
Lep SM4609002-0EN
Issued 09-07
Copyright
9002-8
STEP 14
STEP 17
Apply grease by hand on the crown wheel.
STEP 18
Start the engine and turn the upperstructure by one
eighth of a turn. Shut down the engine.
STEP 19
Apply grease again by hand on the crown wheel.
STEP 20
Repeat the operation until all teeth of the turntable are
properly lubricated.
NOTE: Refer to the specifications on page 2 for the
quantity of grease to be applied.
Open the left-hand side door. Reconnect the earth
cable (1) to the battery. Close the LH side door.
STEP 21
STEP 15
Refer to page 10, "Installing the counterweight" and put
the counterweight back in place.
WARNING: If your hand is in the access port of

the crown wheel when the upperstructure is
revolving, you could get seriously injured.
Before applying grease by hand on the crown
wheel, always check that the bucket or the tool
is placed on the ground and that the engine is
shut down.
CD01K066
Apply grease to the grease fittings on the turntable.

Install a new seal ring.
STEP 16
1
2
3
CS02C505
Remove the three screws (1) that fasten the access

door (2) to the upperstructure. Remove the access door
(2). Scrap the seal (3).
Lep SM4609002-0EN
Issued 09-07
Copyright
9002-9
STEP 22
Install the access door with the seal, on the machine.
Fasten it in position with the three screws and the locking washers.
STEP 23
CI00F500
Install the lower housing under the machine using

screws and washers.
Lep SM4609002-0EN
Issued 09-07
Copyright
9002-10
COUNTERWEIGHT
Description
09-009-0A
1
2
3
COUNTERWEIGHT
SCREW
WASHER
Lep SM4609002-0EN
4
5
SHIM
INSULATING MATERIAL
Issued 09-07
Copyright
9002-11
Removal
STEP 3

STEP 1
Attach a suitable lifting device to the lifting rings of the

counterweight (1). Use the total movement of the lifting
device.
weight of the counterweight.
STEP 2
Remove the screws (2) and the flat washers (3) that
fasten the counterweight (1) to the undercarriage.
Raise the counterweight (1) and remove it from the
machine. Place it on flat ground. Remove the lifting
equipment.
STEP 4
Remove the shims (4) from the undercarriage anchorage points.
NOTE: Count the number of shims (4), remove them
from each anchorage point. Keep each set of shims (4)
to facilitate reassembly.
STEP 5
Check the state of the insulating material (5) installed
on the counterweight. Change the insulating material if
it is damaged.
Lep SM4609002-0EN
Issued 09-07
Copyright
9002-12
Installation
STEP 4

STEP 1
Install the screws (2) as well as the flat washers (3) to

attach the counterweight (1). Tighten to the torques
Attach a suitable lifting device to the lifting rings of the
counterweight (1).
weight of the counterweight.
STEP 5
Remove the lifting device from the lifting rings of the
counterweight (1).
STEP 2
Install the same number of shims (4) as those removed
in step 4 of removal, at each anchorage point of the
counterweight on the undercarriage.
STEP 3
Move the counterweight (1) into position on the undercarriage. Align the ports of the counterweight with those
on the undercarriage.
Lep SM4609002-0EN
Issued 09-07
Copyright
9003
Section
9003
BOOM, DIPPER AND BUCKET
CNH
Lep SM4609003-0EN

Printed in France
September 2007
Copyright
9003-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 2
BUCKET.......................................................................................................................................................................... 3
Description .................................................................................................................................................................. 3
Removal ..................................................................................................................................................................... 4
Installation .................................................................................................................................................................. 4
Shimming the bucket ................................................................................................................................................. 5
Removal and installation of Bucket Yoke and Connecting rod .................................................................................. 6
DIPPER ........................................................................................................................................................................... 8
Description .................................................................................................................................................................. 8
Removal ..................................................................................................................................................................... 9
Installation .................................................................................................................................................................. 9
BOOM ........................................................................................................................................................................... 11
Description ................................................................................................................................................................ 11
Removal ................................................................................................................................................................... 12
Installation ................................................................................................................................................................ 13
SPECIFICATIONS
See Section 1002
Lep SM4609003-0EN
Issued 09-07
Copyright
9003-3
BUCKET
Description
13
21
14
23
20
17
20
20
17 20
16
13
10
15
21
14
19
22
15
4
18
18
22
12
19
11
7
24
2
3
24
JS0127B
1
2
3
4
5
6
7
8
9
10
11
12
LOCKING PIN
PIN
BUCKET
YOKE
LOCKING PIN
PIN
DUST SEAL
GREASE FITTING
NUT
SCREW
PIN
SHIM
Lep SM4609003-0EN
13
14
15
16
17
18
19
20
21
22
23
24
CONNECTING ROD
GREASE FITTING
BUSHING
BUSHING
SHIM
DUST SEAL
DUST SEAL
LINKAGE SEAL
LINKAGE SEAL
LINKAGE SEAL
LINKAGE SEAL
RETAINING RING
Issued 09-07
Copyright
9003-4
Removal
STEP 4
STEP 1
Place the bucket flat on flat, level ground. Operate the
attachment controls so that the dipper/bucket
connecting pin is not under load from the weight of the
dipper. Shut down the engine.
STEP 2
Start the engine, disengage the attachment from the

bucket and save the linkage seals for re-use.
Installation
STEP 1
Make sure the bucket is in a stable position.
Remove the retaining rings and pins.
STEP 2
STEP 3
Remove the bucket pins.
Lep SM4609003-0EN
Install the linkage seals on the dipper bushing shoulders.

Change them if necessary. Start the engine. Extend the
bucket cylinder rod to bring it into its housing. Stop the
engine and remove the starter switch key.
Issued 09-07
Copyright
9003-5
STEP 3
Shimming the bucket

The machine is equipped with a bucket play adjusting
system which eliminates play that develops at the
bucket/dipper linkage due to wear. This system delays
the effects of wear and gives longer life to bushings and
pins.
NOTE: Incorrect adjustment of the play can cause
friction, abnormal noises or excess play and damage
the O-rings.
Adjusting the play

Place the bucket flat, lying on the ground.
1
J
Install the dipper/bucket linkage pin and then install the
retaining pin and ring. Start the engine. Bring the bucket
rod into its housing, stop the engine and remove the
starter switch key.
STEP 4
CD00E121
Check the play (J) between the dipper and the bucket
lug. If the play (J) exceeds 4 mm, remove the four
screws and the cap (1), then the shims (2). Use the
shims (2) as a feeler gauge and calculate the number of
shims necessary to eliminate the play (J). Install the
necessary number of new shims. Reinstall the cap (1)
and the four screws.
NOTE: When the screws on the cap (1) are tightened,
the inner bushing moves towards the dipper and the
play is eliminated.
Install the connecting rod/bucket linkage pin and then
install the retaining pin and ring. Push the seals back into
their housings. Adjust the dipper/bucket shimming. See
"Shimming the backhoe bucket". Grease the linkage pins.
Lep SM4609003-0EN
IMPORTANT: It is recommended to maintain a play of

about 1.2 mm. If the play is insufficient, it may cause wear
by friction or seizing.
IMPORTANT: The inner bushing has a stud which
prevents the bushing from turning. The cap (1) has an
orifice in its inner surface. Make sure that the stud is
inserted in that orifice when the cap is installed (1).
Issued 09-07
Copyright
9003-6
Removal and installation of Bucket

Yoke and Connecting rod
STEP 3
Remove the bucket. (For details, see page 4 "Removal

and Installation of Bucket".)
STEP 1
Place the bucket yoke (1) parallel to the ground.
STEP 2
Use the bar hammer (1) and the holding-up bar (2) to
push out the pin (3), and remove the bucket yoke (4).
Remove double nuts (1) and (2), and then pull out bolts
(3) and (4).
Lep SM4609003-0EN
Issued 09-07
Copyright
9003-7
STEP 4
Use a bar hammer (1) and the holding-up bar (2) to

push out the pin (3), and remove connecting rod (4) and
(5). If the pin is difficult to pull out, it is being loaded.
When pulling out a pin, take care not to damage the
installed O-ring and dust seal.
When installing parts, clean the pin and pin opening of
each part, and firmly rub them with grease.
NOTE: When installing proceed in the reverse order
from removal. Change linkage seals and bushing, if
necessary.
Lep SM4609003-0EN
Issued 09-07
Copyright
9003-8
DIPPER
Description
5
3
1
2
6
7
10
8
6
13
7
12
8
11
12
JS01274C
1
2
3
4
5
6
WASHER
SCREW
PIN
DIPPER
BOOM
DUST SEAL
Lep SM4609003-0EN
7
8
9
10
11
12
BUSHING
BUSHING
BUSHING
SHIM
SEAL
SEAL
Issued 09-07
Copyright
9003-9
Removal
STEP 6
STEP 1
Remove the bucket, the connecting rods and the yoke,
see page 4.
STEP 2
Start the engine, retract the dipper cylinder rod and
lower the attachment to the ground. Shut down the
engine.
STEP 3
Remove the bucket cylinder and disconnect the dipper
cylinder rod from the dipper, see Section 8005. Attach
the dipper cylinder rod to the boom.
STEP 4
Use a bar hammer (1) and the holding-up bar (2) to

push out the pin (3) and remove the arm (4). If the pin is
difficult to pull out, it is being loaded. When pulling out a
pin, take care not to damage the installed O-ring and
dust seal. When installing parts, clean the pin and pin
opening of each part, and firmly rub them with grease.
STEP 7
Start the engine, move the machine backwards to
separate the dipper from the boom. Lower the boom to
the ground and shut down the engine.
STEP 8
Lower the dipper to the ground and remove the lifting
equipment from the dipper.
Attach a suitable lifting device to the dipper. Take up
any slack on the lifting slings, since the dipper has to be
supported before lifting.
STEP 5
STEP 9
Remove and scrap the dust seals.
NOTE: Perform step 10 only if the bushings have to be
changed.
STEP 10
Remove the bushings from the dipper or from the
boom, using a hammer and a suitable drift on the outer
diameter of the bushing.
Installation
NOTE: Perform step 1 only if the bushings have been
removed.
STEP 1
Using a suitable sleeve, install the bushings.
STEP 2
Remove the screw (1).
Install new dust seals on the dipper.
STEP 3
Attach a suitable lifting device to the dipper. Move the
dipper into position near the machine.
Lep SM4609003-0EN
Issued 09-07
Copyright
9003-10
STEP 4
Start the engine and move the machine forwards so
that the boom is aligned with the dipper. Check the
alignment of the pin bores on the boom and the dipper.
STEP 5
Install the pin (3) and the lock bolt (1).
STEP 6
Using a set of feeler gauges, check that the play
between the boom and the dipper is 4.5 to 5.5 mm . If
necessary, remove the pin (3) and add one or more
shims as required to arrive at the correct clearance.
Install the pin (3).
STEP 7
Remove the lifting device from the dipper.
STEP 8
Connect the dipper cylinder rod to the dipper and install
the bucket cylinder, see Section 8005.
STEP 9
Install the bucket, see page 4.
STEP 10
Bleed the cylinders, see Section 8000.
STEP 11
Grease the linkages.
Lep SM4609003-0EN
Issued 09-07
Copyright
9003-11
BOOM
Description
6
7
5
7
6
5
2
3
JS01275B
1
2
3
4
5
6
7
WASHER
SCREW
PIN
BOOM
SHIM
DUST SEAL
BUSHING
Lep SM4609003-0EN
Issued 09-07
Copyright
9003-12
Removal
STEP 7
STEP 1
Remove the dipper, see page 9.
STEP 2
Start the engine and lower the boom to the ground.
STEP 3
Remove the dipper cylinder, see Section 8005. Do not
remove the vacuum pump from the hydraulic reservoir.
STEP 4
Disconnect the boom cylinder rods from the boom, see
section 8005
STEP 5
Wrap a nylon sling (1) around the pin that was installed
in step [4], and fix it with the crane.
STEP 8
Remove the grease nipple (1) and inser a batten (2) to

the root of the boom cylinder.
STEP 6
Remove the lock bolt (1).
STEP 9
Install the pin (1) that was removed in section 8005.

Install the bolt (3) with 2 lock nuts (2) and also install
the securing ring (4).
Lep SM4609003-0EN
Use a 24-mm slide hammer (1) to remove the pin (2).
Issued 09-07
Copyright
9003-13
STEP 10
STEP 13
Disconnect all the hoses. Mark the hoses and pipes so

that the connectors match at the time of assembly. Use
caps or plugs to cover the hoses and pipes to prevent
the entry of water, dust or dirt. Clean the hoses and
pipes by spraying with a parts cleaner to prevent
scratches and prevent dirt from accumulating on the
connectors.
Remove and scrap the boom dust seals (6).
STEP 11
Disconnect the boom cylinder rods from the boom, see
Section 8005.
refer to the drawing on page 11.
STEP 12
NOTE: Perform step 12 only if the bushings (7) have to

be changed.
STEP 14
Remove the bushings (7) from the boom, using a
hammer and a suitable drift on the outer diameter of
the bushing.
Installation
NOTE: Perform step 1 only if the bushings (7) have
been removed.
STEP 1
Using a suitable sleeve, install the bushings (7) on the
boom.
STEP 2
Install new dust seals (6) on the boom.
STEP 3
Reverse the machine and remove the boom (1).
Attach a suitable lifting device to the boom. Raise the

boom and move it into position, check the alignment of
the boom and chassis orifices.
STEP 4
Install the pin (3) and the lock bolt (1).

Lep SM4609003-0EN
Issued 09-07
Copyright
9003-14
STEP 5
Using a set of feeler gauges, check that the play
between the boom and the chassis is 3.5 to 5.5 mm. If
necessary, remove the pin (3) and add one or more
shims (5) as required to arrive at the correct clearance.
Install the pin (3).
STEP 6
Connect the boom cylinder rods to the boom, see
Section 8005.
STEP 7
Start the vacuum pump and remove the plugs from the
hoses. Connect the supply hoses at the bottom of the
boom.
STEP 8
Install the dipper cylinder on the boom, see Section
8005.
STEP 9
Install the dipper and the bucket, see page 8.
STEP 10
Bleed the cylinders, see Section 8000.
STEP 11
Grease the linkages.
Lep SM4609003-0EN
Issued 09-07
Copyright
Section
SEAT AND SAFETY BELT
CNH
Lep SM4609004-0EN

Printed in France
September 2007
9004
9004
Copyright
9004-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
OPERATOR'S SEAT ...................................................................................................................................................... 3
Description ................................................................................................................................................................. 3
Removal ..................................................................................................................................................................... 4
Installation .................................................................................................................................................................. 7
SAFETY BELT ............................................................................................................................................................... 8
Removal ..................................................................................................................................................................... 8
Installation .................................................................................................................................................................. 8
SPECIFICATIONS
Weight of the operator's seat.................................................................................................................. 46 kg (101.41 lb)
Lep SM4609004-EN
Issued 09-07
Copyright
9004-3
OPERATOR'S SEAT
Description
10
9
6
7
2
CS02A504
1
2
3
4
5
OPERATOR'S SEAT
MASK
BOOT
RAIL
REAR CONTROL ARM BRACKET
Lep SM4609004-0EN
6
7
8
9
10
SHOCK ABSORBER
BRACKET
FRONT CONTROL ARM BRACKET
CYLINDER
BULB
Issued 09-07
Copyright
9004-4
Removal
STEP 5
STEP 1
2
1
CD00G049
JS00163A1

the ground.
Loosen and remove the screw (1) that retains the function cancellation lever (2). Remove the lever.
STEP 6
STEP 2
STEP 3
Move the operator's seat as far forward as possible.
STEP 4
CD00G050
Loosen and remove the three screws that hold the inner
cab access bar. Remove the access bar.
STEP 7
1
CD00G048
Lift the boot. Loosen and remove the four screws (1)
from the front portion of the control arm.
NOTE: Steps 5 to 7 are to be carried out only for the LH
control arm.
2
1
CD00G051
Label and disconnect the electrical connectors (1),

remove the compartment control casing assembly (2).
Lep SM4609004-0EN
Issued 09-07
Copyright
9004-5
NOTE: For the LH control arm, do not carry out step 8.
STEP 11
STEP 8
Lift the upper portion of the control arm and position it

to the side.
STEP 12
CD00G066
Remove the trim then remove the air-conditioning box

using the four screws. Remove the latter.
CD00G117
STEP 9
Loosen and remove the two upper screws as well as

the two lower screws that hold the front portion of the
control arm.
NOTE: For the RH control arm, do not carry out

steps 13 and 14.
STEP 13
1
1
CD00G052
Loosen and remove the four screws (1) from the rear
portion of the control arm.
STEP 10
CD00G118
Loosen and remove the screws that hold the LH side

portion of the control arm.
CD00G053
Loosen and remove the two screws (1) that hold the
arm angle adjustment lever, then remove the lever.
Lep SM4609004-0EN
Issued 09-07
Copyright
9004-6
STEP 14
STEP 16
1
1
CD00G058
CD00G120
Loosen from the LH side, the rod (1) that links the function cancellation lever to the safety bar (2).
Loosen and remove the two front retaining screws (1) of

the control arm to the front seat bracket.
STEP 15
STEP 17
LH side
2
1
1
1
CD00G121
CD00G059
RH side
Loosen and remove the two rear retaining screws (1) of

the control arm to the rear seat bracket.
CD00G119
Loosen and remove the four screws that fasten the

plate (1) to the bracket (2).
Lep SM4609004-0EN
Issued 09-07
Copyright
9004-7
STEP 18
STEP 20
CD00G127
Move the LH control arm (1) on the cab side, keep it in

this position using suitable lifting equipment.
NOTE: For the RH control arm, position it behind the
cab.
STEP 19
CD00G123
Remove the carpet, loosen then remove the eight

retaining screws from the seat. Remove the seat from
the cab, with the help of an assistant.
NOTE: The seat weighs 46 kg (101.41 lb).
Installation
removal.
1
1
1
CD00G122
Remove the trim in front of the seat using the four

screws (1).
Lep SM4609004-0EN
Issued 09-07
Copyright
9004-8
SAFETY BELT
Removal
STEP 4
STEP 1
CD00G125
JS00163A1

the ground.
STEP 2
Loosen and then remove the screw (2) and the washer.
Remove the inertia-reel.
Installation
removal.
STEP 3
CD00G124
Loosen then remove the retaining screw (1) and the

washer. Remove the seat fastener.
Lep SM4609004-0EN
Issued 09-07
Copyright
Section
9005
9005
CAB AND CAB EQUIPMENT
CNH
Lep SM4609005-0EN

Printed in France
September 2007
Copyright
9005-2
TABLE OF CONTENTS
CAB ............................................................................................................................................................................... 3
Removal .................................................................................................................................................................... 3
Installation ................................................................................................................................................................. 6
HEATER ........................................................................................................................................................................ 9
Description ................................................................................................................................................................ 9
Removal .................................................................................................................................................................. 10
Installation ............................................................................................................................................................... 11
WINDSHIELD WIPER MOTOR ...................................................................................................................................
Description ..............................................................................................................................................................
Removal ..................................................................................................................................................................
Installation ...............................................................................................................................................................
Lep SM4609005-0EN
13
13
14
15
Issued 09-07
Copyright
9005-3
CAB
Removal
STEP 7
Remove the radio, if fitted.
STEP 1
STEP 8
JS00163A

the ground.
STEP 2
Remove the trim panel at the rear of the cab, taking

care to disconnect the connector for the cigarette lighter
and the solar radiation detector.
STEP 9
STEP 3
1
CD00G004
Open the left-hand side doors. Disconnect the earth

cable (1) from the battery. Close the doors.
Remove the two electronic boxes (1) and (2), see

Section 4003.
STEP 4
Fold the operator's seat-back down and move the seat
as far as possible.
STEP 5
Remove the floor mat from the cab.
STEP 6
Remove the thrust bar on the left-hand side of the cab.
Lep SM4609005-0EN
Issued 09-07
Copyright
9005-4
STEP 10
STEP 14
4
3
5
CD00G006
Disconnect the windshield washer pipe and remove the

retaining clip.
STEP 15
Remove the windshield wiper motor, see page 13 in
this section.
STEP 16
Remove the relays and the relay retaining plate (3).
Remove the upper right-hand side trim panel and

remove the display.
STEP 11
STEP 17
Remove the controller brackets (4) and (5).
STEP 12
CD00G005
Remove the screws (1) which fasten the rear ventilation

and remove the two conduits.
STEP 13
Remove the connectors (2) at the rear of the cab.
Remove the pollen filter guard, remove the pollen filter

and remove the pollen filter conduit.
Lep SM4609005-0EN
Issued 09-07
Copyright
9005-5
STEP 18
STEP 20
Remove the working light from the top of the cab.

Retract the radio aerial. Install suitable lifting rings on
the top of the cab. Install lifting equipment.
STEP 19
Remove the screws and washers which fasten the cab
to the frame.
NOTE: Keep away from the cab while it is being
lowered. Make sure that the cab is not damaged during
lifting or lowering. Room for manoeuvre is very limited
at the rear, on the sides and inside the cab.
Using the lifting equipment, carefully raise the cab until

it is completely away from the machine, then lower it to
the ground.
Lep SM4609005-0EN
Issued 09-07
Copyright
9005-6
Installation
NOTE: Keep away from the cab while it is being
lowered. Make sure that the cab is not damaged during
lifting or lowering. Room for manoeuvre is very limited
at the rear, on the sides and inside the cab.
STEP 1
Install suitable lifting rings on the top of the cab. Using

suitable lifting equipment, raise the cab. Guide the cab
so that it is correctly aligned with the mounting studs
and orifices in the upperstructure frame.
STEP 2
Install the screws and washers which fasten the cab to
the frame.
STEP 3
Install the working light on the top of the cab.
STEP 4
Install the windshield wiper motor, see page 13 in this
section.
Lep SM4609005-0EN
Issued 09-07
Copyright
9005-7
STEP 5
STEP 9
Use the screws to install the display and connect it to

the electrical harness.
STEP 6
1
Install the electronic control box support brackets.
STEP 10
Connect the electrical harnesses together.
STEP 11
Install the pollen filter and the pollen filter conduit.

Using screws (1), fasten the pollen filter housing (2) to
the cab.
STEP 7
Reconnect the blower motor conduit to the ventilation
conduit at the front of the cab. Reconnect the ventilation
conduit at the rear of the cab.
CD00G004
STEP 8
Install the relays and the two controllers, see Section

4003.
.
CD00G006
Connect the windshield washer pipes together and

attach the retaining clip.
Install the trim panel at the rear of the cab, taking care
to reconnect the cigarette lighter connector and the
solar radiation detector.
Lep SM4609005-0EN
Issued 09-07
Copyright
9005-8
STEP 12
Install the radio, if fitted.
STEP 13
Install the access bar, using screws and washers.
STEP 14
Install the floor mat.
STEP 15
Open the left-hand side doors. Reconnect the battery

cable (1) to the battery. Close the doors.
Lep SM4609005-0EN
Issued 09-07
Copyright
9005-9
HEATER
Description
12
3
1
10
6
11
8
7
2
CS02C514
1
2
3
4
5
6
CAB REAR VENTILATION CONDUIT

CAB LOWER VENTILATION CONDUIT
PLUG
POLLEN FILTER
CONDUIT
SCREW
Lep SM4609005-0EN
7
8
9
10
11
12
HEATER HOSE
RETAINING CLIP
UNION
UNION
HEATER ASSEMBLY
CONTROL BLOCK
Issued 09-07
Copyright
9005-10
Removal
STEP 5
STEP 1
WARNING: Boiling cooling fluid can spurt out

when the radiator cap is removed. To remove
the cap, proceed as follows: Wait until the
system has cooled down and then turn the cap
slightly and wait for all the pressure to be
released. You can be seriously scalded if the
radiator cap or expansion reservoir cap is
removed too quickly. For checking and
maintenance of the cooling system, refer to the
maintenance instructions.
Make sure that the radiator has cooled down and

remove the radiator cap.
JS00163A

the ground.
STEP 2
STEP 3

STEP 4
Raise the engine hood and lock it in the raised position.
STEP 6
Use a container of suitable capacity and drain the oilcooler (see Section 2001).
STEP 7
Remove the operator's seat from the cab (see Section
9004).
STEP 8
to disconnect the connector for the cigarette lighter and
the solar radiation detector.
STEP 9
Disconnect the electric blower supply harness.
Lep SM4609005-0EN
Issued 09-07
Copyright
9005-11
STEP 10
Installation


STEP 1
Install the heater in the cab, using the screws (6), brake
washers and flat washers.
STEP 2
8
7
4
CD00G044
Unscrew the hose clips (8) and disconnect the heater

hoses (7).
STEP 11
Remove the ventilation conduits (1) and (2) from the
cab.
STEP 12
Install the conduit (5), the pollen filter (4) and the pollen
filter guard.
STEP 3
Install the heater ventilation conduits (1) and (2).
STEP 4
4
8
Remove the pollen filter guard, remove the filter (4) and
remove the conduit (5).
STEP 13
Remove the screws (6) that secure the heater to the
cab. Remove the heater from the cab.
Lep SM4609005-0EN
CD00G044
Install the heater hoses (7) and tighten the retaining

clips (8).
Issued 09-07
Copyright
9005-12
STEP 5
Connect the blower supply electrical harness.
STEP 6
STEP 10
Start the engine and run it at idle speed for one minute.
STEP 11
Add cooling fluid according to requirement in the
expansion reservoir.
WARNING: Boiling cooling fluid can spurt out

when the radiator cap is removed. To remove
the cap, proceed as follows: Wait until the
system has cooled down and then turn the cap
slightly and wait for all the pressure to be
released. You can be seriously scalded if the
radiator cap or expansion reservoir cap is
removed too quickly. For checking and
maintenance of the cooling system, refer to the
maintenance instructions.
to reconnect the cigarette lighter connector and the
solar radiation detector.
STEP 12
STEP 7
Start the engine and run it at maximum speed until it

reaches normal working temperature.
Install the operator's seat in the cab (see Section

9004).
STEP 8
Pour suitable cooling fluid in the radiator (see Section
2001).
STEP 9
STEP 13
STEP 14
Let the oil-cooler cool.
STEP 15
When the radiator feels cold, remove the caps from the
radiator and the expansion reservoir. Top up if
necessary.
STEP 16
Close the left-hand side doors.
Open the left-hand side doors. Reconnect the earth

cable (1). Close the doors.
Lep SM4609005-0EN
Issued 09-07
Copyright
9005-13
WINDSHIELD WIPER MOTOR

Description
4
11
9
8
10
2
1
7
6
3
CI00G502
1
2
3
4
5
6
PROTECTIVE FLAP
WINDSHIELD WIPER ARM
NUT
WINDSHIELD WIPER MOTOR
RUBBER CAP
NUT
Lep SM4609005-0EN
7
8
9
10
11
FLAT WASHER
PLASTIC SUPPORT
SCREW
ELECTRICAL HARNESS
SCREW
Issued 09-07
Copyright
9005-14
Removal
STEP 6
STEP 1
Note the position of the windshield wiper arm (2).

Remove the windshield wiper arm (2) from the
windshield wiper motor (4) by pulling it off the
windshield wiper motor shaft.
STEP 7
Remove the rubber cap (5).
STEP 8
Remove the nuts (6), washer (7) and plastic support (8)
from the windshield wiper motor shaft.
STEP 9
JS00163A

the ground.
STEP 2
STEP 3
CD00G133
Remove the upper right-hand trim.
STEP 10
A
A
STEP 4
From the front of the cab, raise the protective flap (1)
located on the lower portion of the windshield wiper
arm (2).
STEP 5
Remove the nut (3).
CD00G134
Remove the lower front trim inside the cab, by the

screw(s) (A).
STEP 11
Disconnect the electrical harness (10) from the
windshield wiper motor (4).
STEP 12
Remove the screws (9) and (11) from the windshield
wiper motor. Remove the windshield wiper motor.
Lep SM4609005-0EN
Issued 09-07
Copyright
9005-15
Installation
STEP 8

Turn back the flap (1) located on the lower portion of

the windshield wiper arm (2).
STEP 1
STEP 9
Place the windshield wiper motor (4) in position on the

cab bracket. Connect the windshield wiper motor
connector (4) to the electrical harness (10).
STEP 2
Install the windshield wiper motor (4) on the cab pillar,
using the screws (9) and (11).
STEP 3
Open the left-hand side doors. Connect the earth cable

(1). Close the doors.
STEP 10
Switch on the windshield wiper motor and check that
everything is working correctly.
CD00G134
Install the right-hand front trims in the cab using the

screws.
STEP 4
Install the support (8), washer (7) and the two nuts (6).
Tighten the nuts.
STEP 5
Install the rubber cap (5).
STEP 6
Install the windshield wiper arm (2) on the windshield
wiper motor shaft (4), positioning the windshield wiper
arm (2) in the same position as was noted at
disassembly.
STEP 7
Install the nut (3) on the windshield wiper motor shaft.
Tighten the nut.
Lep SM4609005-0EN
Issued 09-07
Copyright
9005-16
NOTES
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Lep SM4609005-0EN
Issued 09-07
Copyright
Section
9007
AIR CONDITIONER
9007
CNH
Lep SM4609007-0EN

Printed in France
September 2007
Copyright
9007-2
TABLE OF CONTENTS
SPECIFICATIONS ........................................................................................................................................................... 2
SPECIAL TORQUE.......................................................................................................................................................... 3
AIR CONDITIONER ......................................................................................................................................................... 4
Description ................................................................................................................................................................... 4
Disassembly and assembly .......................................................................................................................................... 5
SPECIFICATIONS
Capacity of the system ............................................................................................................................... 1.350 0.05 kg
Type of cooler ................................................................................................................................................ HFC (R) 134a
Receiver dryer max. setting pressure of the system with full gas load................................................................. 3.14 Mpa
Table 1
Replacement part
Oil level adjustment
Compressor
Measure the oil volume in compressor that is removed.

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

compressors. Refer to the nameplate attached to the
compressor, which has indications for the oil type.
NOTE: Before starting the operation, stop the engine
and turn off the power for air conditioner related
devices. Avoid water or dust from entering the
refrigerating circuits. In addition, do not leave the piping
unattached from the machine. Avoid conducting piping
removal or fitting work under rainy conditions. When the
work is completed, check that the faulty parts have
been fully repaired by running the air conditioner.
Lep SM4609007-0EN
Issued 09-07
Copyright
9007-3
SPECIAL TORQUE
Table 2
Pipe fastening section
Tightening torque Nm
D hose and compressor (M8 bolt)
20 to 30
S hose and compressor (M8 bolt)
20 to 30
D hose and condenser (1/2 inch nut)
20 to 25
Condenser and L hose (L pipe) (8 mm nut)
12 to 15
L hose (L pipe) and receiver dryer (M 6 bolt)
8 to 12
S hose, L hose and expansion valve

(M6 x P1.25)
8 to 12
Table 3
Category
Type
Nominal diameter
(mm)
Pitch
(mm)
Tightening torque
Nm
Bolt
7T
M6
1.0
8 to 12
M8
1.25
20 to 30
9T
Nut
Pipe
diameter
M10 (air conditioning unit mounting section)
17 to 19
M10
1.25
40 to 54
M10
1.5
37 to 51
M8
1.25
24 to 36
M10
1.25
56 to 76
M10
1.5
53 to 72
8 mm
1.5
12 to 15
1/2 inch
1.5
20 to 25
5/8 inch
1.5
30 to 35
NOTE:
About oil capacity for compressors
SD7H13WM7359 X1 Series compressors are filled with
135 cc of oil (SP-10). Low oil level may cause it to seize
up at high speeds and reduce durability while excessive
oil may reduce its cooling performance. While the air
conditioning is running, the oil is distributed in the
refrigerating circuits. Therefore, the oil level must be
adjusted following the instructions in table 1 when cha
nging parts.
Lep SM4609007-0EN
Issued 09-07
Copyright
9007-4
AIR CONDITIONER
Description
2
4
5
10
11
7
9
CRPH06B065H01
1
2
3
4
5
6
BLOWER MOTOR RELAY

CONTROLLER
INSIDE AIR FILTER
INSIDE/OUTSIDE AIR SWITCH-OVER MOTOR ACTUATOR
BLOWER CASE
AIR MIX MOTOR ACTUATOR
Lep SM4609007-0EN
7
8
9
10
11
HEATER CORE
MODE SWITCH-OVER MOTOR ACTUATOR
SCREW
INTAKE CASE
SCREW
Issued 09-07
Copyright
9005-5
Disassembly and assembly
STEP 5
IMPORTANT: Service work on air-conditioning circuits

must be carried out by approved service engineers.
1
2
NOTE: Never attempt to service the air conditioning

system unless you are completely familiar with air
conditioning and the safety precautions which must be
followed when handling liquid refrigerant. Liquid
refrigerant can cause severe and painful frostbite.
Contact your dealer, who is experienced in servicing
and handling of refrigerants.
NOTE: When fastening the piping connection for
refrigerating circuits, apply special oil (SP-10) to Orings and fasten the connecting parts using tightening
torque specified in Table 2, page 3. Further, tighten
screws and bolts using torque specified in Table 3,
page 3.
STEP 1
Remove the inside air filter (3), and remove the 4
screws (3) (5 x 14) to remove the intake case (10)
(see page 4).
3
CRPH06B067A01
Drain the cooling water, detach the heat hose and then
remove the 2 screws (4) (5 x 16).
Remove the pipe clamp (2) and the AHC bracket (3),
and then pull out the heat core (1).
STEP 6
1
STEP 2
Remove the blower case (5) by removing the 3 screws
(11) (5 x 14) that mount the blower case to the unit
case (see page 4).
STEP 3
1
2
CRPH06B068A01
3
5
Remove the rod D (1) from the rod holder (2) mounted
on the lever of the mode motor actuator.
4
CRPH06B066A01
After removing the cooling hose (5), remove the 3

bolts (4) (5 x 16) fitted under the blower case (1) and
pull out the blower motor (2).
NOTE: Do not remove the fan from the blower motor.
STEP 4
Remove the 2 screws (6) (4 x 14) under the blower
case (1) and pull out the blower controller (3).
NOTE: Do not disassemble the blower controller.
Lep SM4609007-0EN
Issued 09-07
Copyright
9007-6
STEP 7
STEP 9
32
B
3
5
4
4
CRPH06B069A01
Remove the motor actuator mounted on the lower unit

case (5) and the upper unit case (1) by removing 3
screws.
Remove the 11 mounting screws (5 x 16) from the
lower unit case (5) and the upper unit case (1).
Pull upward the upper unit case (1).
WARNING: Paying attention not to have evaporation
sensor cords caught by the case.
STEP 8
CRPH06B071B01
Installing the evaporation sensor:
NOTE: Attach the evaporation sensor to the holder,

place the tip of the holder and sensor in place as shown
in the figure above.
7
3
6
(1) Insert sensor holder into 13th and 14th

columns.
(2) Insert sensor holder into 5th and 6th columns.
(3) 3RD column.
(4) Ensure no unnecessary looseness.
(5) Do not allow tip of the thermistor to extrude
from tube to the left.
CRPH06B070A01
Pull out the evaporator (2) with its heat insulating

material attached from the lower unit case.
Pull out the evaporation sensor (4) with its sensor
holder attached from the evaporator.
Remove the 2 hexagon bolts (6) (M5x40) from the
evaporator, and then, remove the expansion valve (3)
from evaporator.
Install O-rings (7) (5/8 and 1/2 NFO rings) onto a new
evaporator and then fit the expansion valve.
NOTE: Special care should be taken while installing to
avoid O-ring engagement. Do not reuse O-rings. Install
O-rings with bare hands.
Lep SM4609007-0EN
Issued 09-07
Copyright
9005-7
STEP 10
STEP 12
Replacement of the inside/outside air
switch-over motor actuator:
CRPH06B072A01
Remove the rod clamp (C) interlocking the mode motor

actuator and mode cam by pushing to the direction of
ARROW.
Remove 3 mounting screws from the motor actuator
and remove the motor actuator with its rod clamp and
lever attached from the unit.
Remove the rod clamp and lever. Then, install them on
a new motor actuator in the reverse order of the
disassembly.
E
CRPH06B074A01
Remove the screw fixing the motor actuator with its

lever (E) attached, and remove the motor actuator.
Remove the lever from the motor actuator. Install a new
motor actuator in the reverse order of the disassembly.
STEP 11
Replacement of the air mix motor actuator:
B
A
CRPH06B073A01
Remove the rod (B) from the lever by pushing the rod
clamp (A), which is attached on the lever of the motor
actuator, to the direction of ARROW.
Remove the 3 mounting screws from the motor
actuator, and remove the motor actuator with its rod
clamp and lever attached from the unit.
Remove the rod clamp and lever from the motor
actuator. Install a new motor actuator in the reverse
order of the disassembly.
Lep SM4609007-0EN
Issued 09-07
Copyright
9007-8
NOTES
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Lep SM4609007-0EN
Issued 09-07
Copyright
27
K1
K2
MA
REG
D1
ITEM
VB
VA
25
26
B45
* 30
MB
29 *
29 *
REG
22
28
83
P2
VB
AU
Dr
L1
T1
B1
VA
L2
P3
P2
P2
B2
P3
T1
T1
Pil
T2
MB
MA
Pil
P1
21
15
23
21
23
Pil
T2
T2
Pa9
GA
P1
GB
MU
A=
MAIN RELIEF (STANDARD)
31.4 MPa / 314 Bar / 4554 PSI
A=
MAIN RELIEF (BOOST)
34.3 MPa / 343 Bar / 4974 PSI
B=
BOOM RAISING PORT SECONDARY RELIEF
36.3 MPa / 363 Bar / 5264 PSI
B1/B2 =
RELIEF ON BOOM HBCV
39.2 MPa / 392 Bar / 5685 PSI
C=
BOOM LOWERING PORT SECONDARY RELIEF
36.3 MPa / 363 Bar / 5264 PSI
D=
DIPPER OUT PORT SECONDARY RELIEF
36.3 MPa / 363 Bar / 5264 PSI
D1 =
RELIEF ON DIPPER HBCV
39.2 MPa / 392 Bar /5685 PSI
E=
DIPPER IN PORT SECONDARY RELIEF
36.3 MPa / 363 Bar / 5264 PSI
F=
BUCKET OPEN PORT SECONDARY RELIEF
36.3 MPa / 363 Bar / 5264 PSI
G=
BUCKET CLOSE PORT SECONDARY RELIEF
36.3 MPa / 363 Bar / 5264 PSI
H=
PILOT PRESSURE RELIEF
3.9 MPa / 39 Bar / 565 PSI
I=
RIGHT-HAND SWING PORT SECONDARY RELIEF
29.3 MPa / 293 Bar / 4250 PSI
J=
LEFT-HAND SWING PORT SECONDARY RELIEF
29.3 MPa / 293 Bar / 4250 PSI
K1/K2 =
TRAVEL FORWARD PORT SECONDARY RELIEF
35.8 7.8 MPa / 358 Bar / 5511 PSI
L1/L2 =
TRAVEL REVERSE PORT SECONDARY RELIEF
xxx MPa / xxx Bar / xxx PSI
N1/N2 =
NEGATIVE CONTROL RELIEF
3.38 MPa / 33.8 Bar / 490.2 PSI
Q=
RELIEF VALVE BLOCK COUNTERWEIGHT
27.5 MPa / 275 Bar / 3988 PSI
W1/W2 =
CRUSHER OPTION SECONDARY RELIEF VALVE
xxx MPa / xxx Bar / xxx PSI
Z=
MAIN RELIEF VALVE FAN
25 MPa / 250 Bar / 2626 PSI
51 =
ACCUMULATOR PRECHARGE
1.5 MPa / 15 Bar / 212 PSI
Dr
ITEM
15
Pb7-2
LEFT FORWARD
LEFT REVERSE
RIGHT FORWARD
RIGHT REVERSE
1.8
0.18 MPa
1,8 bar
26 psi T1
42
PS1
T6
Pc5 T2
T4
T5
Ps2
15
Y9
A
B5
OUT
ARM (1)
A9
ARM (2)
Pa5-2
Pa9
IN
Pb5
Pa5-1
15
43
IN
ON
Pa9
OPEN
BUCKET
PC4
D8
83
B4
10
D7
150 MESH
76
15
90
OPTION
A4
DR2'
79
D6
*91
Pb4
B1
D3
79
85
15
T1
42
43
D1
52
B7
DOWN
Pb7-1
BOOM (2)
Pb3
Pa7-2
D7
BOOM (1)
52
UP
Pa3
Pb7-2
29
Pa7-1
Pil
Pa7-2
15
B6
Pa3
T
1.5 MPa
212 psi
15 bar
Y4
LEFT
Pb2
2.5
Pa2
RIGHT
2.5
Y2
P3
*W1
SWING
55
W2
Pb6
BACKWARD
Pa6
C3
0.02 MPa
2.9 psi
0.2 bar
C2
55
3
Y5
10
P0
Y3
TRAVEL
55
42
Pb1
10
55
86
Y1
Y6
HYDRAULIC RESERVOIR
BREATHER
BY-PASS VALVE
SCREEN FILTER
RETURN FILTER
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
HYDRAULIC SWIVEL
TRAVEL MOTOR
SWING MOTOR
TRAVEL MOTOR BRAKE
RIGHT BOOM CYLINDER
LEFT BOOM CYLINDER
DIPPER CYLINDER
BUCKET CYLINDER
BOOM SAFETY VALVE (OPTIONAL)
DIPPER SAFETY VALVE (OPTIONAL)
DIPPER LOAD HOLDING VALVE
BOOM LOAD HOLDING VALVE
FILTER (ULTRA-CLEAN)
OIL COOLER
RETURN MANIFOLD
ACCUMULATOR
6 SOLENOID VALVE BANK
BOOM & BUCKET CONTROL LEVER
SWING & DIPPER CONTROL LEVER
TRAVEL CONTROL PEDAL
BOOM & DIPPER CONTROL SHOCK ABSORBER
PILOT AND RETURN SYSTEM MANIFOLD
FILTER
PILOT SYSTEM MANIFOLD
SECOND OPTION CONTROL VALVE
CONTROL PEDAL (OPTIONAL)
SECOND OPTION CONTROL VALVE
3-WAY SELECTOR (OPTIONAL)
RETURN FILTER (OPTIONAL)
CONTROL SHUTTLE BLOCK (OPTIONAL)
SWING SHUTTLE BLOCK
PILOT CIRCUIT FILTER
SHUT-OFF VALVE (OPTIONAL)
HAND/FOOT CONTROL PILOT FILTER
PILOT FILTER BY-PASS VALVE
HYDRAULIC BREAKER VERSION PLUG
SAFETY VALVE VERSION PLUG
HYDRAULIC PUMP FOR COOLING HYDRAULIC CIRCUIT
COOLING HYDRAULIC MOTOR
SWING PILOT PRESSURE SWITCH
BREAKER / CRUSHER PILOT PRESSURE SWITCH
SECOND OPTION PILOT CIRCUIT 2 PRESSURE SWITCH
BREAKER PILOT PRESSURE SWITCH
UPPER PILOT PRESSURE SWITCH (YELLOW BAND)
TRAVEL PILOT PRESSURE SWITCH
SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH
PUMP PRESSURE SENSOR (P1)
PRESSURE SENSOR (NEGA-CONT)
PUMP PRESSURE SENSOR (P2) (BLUE BAND)
OVERLOAD INDICATOR PRESSURE SWITCH
PRESSURE TEST POINT
SWING PILOT SHUT-OFF SOLENOID VALVE (GREEN BAND)
PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
SWING BRAKE SOLENOID VALVE (PINK BAND)
2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
POWER-UP SOLENIOD VALVE (YELLOW BAND)
CUSHION CONTROL SOLENOID VALVE (LIGHT GREEN BAND)
MAIN PUMP PROPORTIONAL SOLENOID
CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
COOLING HYDRAULIC MOTOR SOLENOID VALVE
PROPORTIONAL SOLENOID FOR COOLING HYDRAULIC MOTOR
Pa1
* 76
B42
15
P1
A4
2.0 MPa
20 bar
290 psi
OFF 1.4 MPa
14 bar
203 psi
P2
P3
PH
PP PA
PT ON
B27
Pr2
Pr1
2
83
B44
BACKWARD
P2
C4
C5
FORWARD
0.103 MPa
14.5 psi
1 bar
P1
B1
A1
82
60
FORWARD A6
B2
* 78
51
C1
TRAVEL
A2
Pb1
PC2
Pa4
A3
B3
43
DR2'
32
Pa1
P5
A7
B2
D2
D1
58
DR2
T4
A8
CLOSE
58
Pa8
D9
B8
Pa5-2
Pb8
0.127 MPa
18.4 psi
1.27 bar
*
B24
*
B28
15
57
Pb9
OUT
0.004 MPa
0.58 psi
0,04 bar
30
B9
A5
0.07 MPa
10.15 psi
0.7 bar
Pil
10
N1
31
Pc1
A1
SECOND OPTION
71
N2
Pa10
121
B1
DR1
73
73
*91
DR1'
41
T3
0.3 MPa
3 bar
43.5 psi
DESCRIPTION
CX460 EXCAVATOR
HYDRAULIC SCHEMATIC
1.
2.
4.
5.
6.
10.
15.
16.
21.
22.
23.
25.
26.
27.
28.
29.
30.
31.
32.
41.
42.
43.
51.
52.
53.
54.
55.
57.
58.
59.
60.
71.
72.
73.
76.
78.
79.
81.
82.
83.
85.
86.
90.
91.
120.
121.
B22.
B23.
B24.
B25.
B26.
B27.
B28.
B42.
B43.
B44.
B45.
M3.
Y1.
Y2.
Y3.
Y4.
Y5.
Y6.
Y7.
Y9.
Y31.
Y32.
RIGHT
LEFT
PRESSURE SETTINGS
16
P1
DESCRIPTION
ON
B26
1.2 MPa
12 bar
174 psi
OFF 0.8 MPa
8 bar
116 psi
15
B4
71
71
B43
LEGEND
P1 PUMP
P4
P5
T4
T5
72
58
P3
P2
P1
T3
T2
55
T1
2S 3S
FORWARD
1S
S2 S3
S1
DOWN
*B25
85
SWING
LEFT
RIGHT
3
1
BOOM
DOWN
BUCKET
OPEN
CLOSE
UP
3
R
T
1
85
B22
59
ON 0.5 MPa
OUT
OFF 0.3 MPa
72.6 psi
5 bar
43.5 psi
3 bar
*
85
*
B23
A1
S1
A2
174 psi B1
12 bar
*
79
Pi2
41
T
2
15
15
116 psi
8 bar
Pb4
5a4
Pa4
P
85
15
Pb9
Pa1
Pb1
Pa6
Pb6
Pa10
182 cm3
Dr
ISUZU
6UZ1X
15
Pb1
CONNECTION ITEM NO
270.0 Kw
1950 tr/mn
a3
A4
Tc
15
A
182 cm3
40.2 cm3
M
15
COMPONENT ITEM NO.

COMPONENT NUMBER
40 cm3
15
PIPING CROSS-OVER
Pi1
15
57
PIPING CONNECTION
42
B2
S2
OFF 0.8 MPa
IN
Y31
ON 1.2 MPa
Y9
COMPONENT BOUNDARY
HOSE
15
A
(REAR)
(FRONT)
LEAK-OFF-RETURN
FORWARD
T
H
OUT
RETURN TO RESERVOIR
10
PILOT SYSTEM CIRCUIT

1
IN
BACKWARD
A2
ARM
BACKWARD
A3
UP
53
85
TRAVEL (RIGHT)
TRAVEL (LEFT)
85
P
PILOT SYSTEM PUMP
Y7
81
54
P2 PUMP
OPTION
121
Y32
43
T
H
15 cm3
120
B4
OPTION ITEM NO
A3
15 cm3
B3
M3
CX460 EXCAVATOR
HYDRAULIC SCHEMATIC
Number 87574463A
Copyright
FUSE C (20A)
BOX FUSE(ATTACHMENT FOR CAB MAIN HARNESS)

65A
YG 451
YL 451
0.85LgR
0.85GB
MOTOR-ACT (AIR-CHG.)
2
3 5
4
CN.33
0.85LR 901
2
3 5
4
CN.34
BrG 461
G 464
0.85GL 413
0.85GL 413
0.85OL 415
10
0.85OL 415
0.85BO 425
11
0.85BO 425
VY 434
12
OR 455
13
PW 255
15
1.25O 895
WR 501
16
WR 501
0.85LgR 502
17
0.85LgR 502
GrR 504
18
GrR 504
BrR 506
19
BrR 506
YR 552
20
YR 552
0.85P 580
21
P 580
0.85PL 581
22
PL 581
0.85BL 661
1.25BY 945
1.25RW 559
1.25B 776
S19
G 854
RG 855
R 852
758,759
2BG 600
S20
RB 856
RW 857
R 853
RG 855
R 853
G 854
CTWT REMOVAL MAIN SW
R 852
O 455
P 255
S18
RY 858
Br 556
B 773
OR 455
O 455
PW 255
P 255
1P-M
CN.T1
1
1P-F
CN.T2
VR 917
5
0.85BrR 916
B 751
OW 546
4
L 913
SENSOR
CYLINDER #1
M14
M15
M20
P1
P2
P3
P4
P5
P6
R1
R3
R4
R5
S1
S2
S3
S4
S5
S6
S7
S8
S9
S10
S11
S12
S13
S14
S15
S16
S18
S19
CYLINDER #6
S20
B47
B21
t C
0.75Y 485
0.75YG(FT)
0.75P 864
0.75RW(PCV1)
0.75W 866
0.75RB(PCV2)
BG 656
G 464
G 465
B3
SUPPLY PUMP
0.75RL(PCV1)
VALVE (PCV1)
Y33
SUPPLY PUMP
VALVE (PCV2)
1.25RG 850
1.25W(INJECTOR POWER1)
1.25RW 851
1.25R(INJECTOR POWER2)
Y34
0.75GW 854
0.75L (INJECTOR ORDER1)
0.75WL 857
0.75LR(INJECTOR ORDER4)
0.75GB 855
0.75LY(INJECTOR ORDER2)
0.75G 856
0.75LW(INJECTOR ORDER3)
0.75WB 858
0.75WR 859
0.75GR(INJECTOR ORDER5)
10
0.75GB(INJECTOR ORDER6)
S21
S25
S51
CYLINDER #5
CYLINDER #3
S52
CYLINDER #2
CYLINDER #4
AIR INTAKE TEMP. SENSOR
0.85BO 492
0.75OL 482
t C
B6
BARO SENSOR
0.85Y 476
0.85YL 486
0.85BY 496
S53
S54
S55
S61
S62
S63
S64
U1
W1
X2
X3
X4
X5
X6
B48
X7
X8
X9
X15
X23
X24
Y1
Y2
AIR CLEANER SENSOR
0.85L 418
Y3
0.85BL 661
S62
Y4
Y5
0.85BO 425
0.85OL 415
t C
B2
Y12
CTWT
LOWER
Y13
(GREEN TAPE)
ARM
TOP
RB 856
Y14
F21
F22
F23
F24
F25
F27
ARM
B 775
BOTTOM
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
(BLEUE TAPE)
1.25RG 850
121
OP-COM1
0.75GB 855
0.75GW 854
119
120
OS-INJECTION2
OS-INJECTION1
0.75WL 857
118
1.25RW 851
0.75G 856
117
116
OP-COM2
OS-INJECTION3
OS-INJECTION4
0.75WR 859
115
OS-INJECTION6
0.75WB 858
114
OS-INJECTION5
OS-PCV1
113
0.75P 865
0.75WB 870
112
111
RAISE
B 774
0.85RY 834
OM-EGR MOTOR1 U
BOOST PRESS.
B45
(YELLOW TAPE)
RW 857
0.75YB 872
t C
PRESS. SENSOR (HBCV)
CTWT
B 772
110
2
B 750
Y31
0.75R 954
OM-EGR MOTOR3 W
B51
Y6
0.75BR 497
SENSOR
HYD.OIL TEMP SENSOR
RY 858
BG 670
109
S55
Br 556
SG-5VRT4(BOOST P)
2LR 915
1
VR 912
330,546
0.85B 756
BG 670
0.85BW 689
010,543
540,541
3LR 060
B 759
2BG 600
2B 700
Y32
0.85BG 641
0.85GrR 437
108
5WR 003
8R 203
630,652,660,661
0.85BG 630
2B 758
1
SG-SLD4(CRANK)
2
3
B 775
1.25YG 944
Br 556
0.75L 951
0.75BY(GND)
RESERVE TANK LSW.
HYDRAULIC MOTOR (FAN)
BG 670
107
0.85BL 422
0.75G 955
0.75L 953
IF-CRANK+
11
BOOST TEMP.
M12
B43
B 772
0.75G 950
0.75P 864
0.85BG 427
106
105
OS-PCV1
0.85L 412
B 772
IF-CRANK-
0.75GB 871
104
102
103
OM-EGR MOTOR2 V
0.85BL 687
99
100
SG-SLD5
0.75L 953
98
IF-G(REM) ANGLE
0.75G 491
101
90
IA-COMMON.R PRESS
82
87
SP-5V5(COM.R&EGR)
IA-COMMON.R PRESS
94
93
IS-EGR PSTN2 V
IS-EGR PSTN1 U
91
92
IS-EGR PSTN3 W
IA-BOOST PRESS
97
OS-PCV2
96
95
89
OS-PCV2
SP-5V4(BOOST P)
88
86
85
84
IA-WATER TEMP
83
IA-FUEL LEAK.TEMP
79
80
SP-5V3(OIL P)
SG-5VRT3(OIL P)
78
77
76
75
74
IA-BOOST TEMP
73
72
IA-INTAKE TEMP
70
71
IA-BARO
69
68
66
67
IA-OIL PRESS
65
64
IA-ACCEL PSTN2
61
63
IA-ACCEL PSTN1
SP-5V2(BARO)
59
60
SG-5VRT2(BARO)
58
57
56
55
54
53
52
IS-DIAG
51
50
49
47
48
IS-MODE MAP2
IS-ENG STOP SW
45
46
IS-IGKEY(START)
44
42
SP-5V1(ACCEL)
40
39
41
SG-5VRT1(ACCEL)
OS-MAIN RELAY
38
CC-KW2000
34
IS-MODE MAP1
IS-MEMORY CLEAR
32
31
29
30
IS-IDLE UP SW
IS-IDLE DOWN SW
IS-IDLE MANU SW
25
IS-MODE MAP0
21
24
IS-IGKEY(ON)
OS-MAIN RELAY
20
SG-SLD1
19
IF-SPD
18
37
CC-CAN-L
CC-CAN-H
14
17
OS-OIL P. LAMP
11
OS-GLOW LAMP
OS-STARTER RELAY
10
OS-GLOW RELAY
OF-TACHO
OS-DIAG LAMP
OS-BOOST LAMP
PS-+B
81
PS-+B
PG-CASE(GND)
62
PG-SIGNAL(GND)
43
PG-SIGNAL(GND)
PG-POWER(GND)
PG-POWER(GND)
36
35
33
28
27
26
23
22
16
15
PG-POWER(GND)
A2
13
ENGINE CONTROLLER
12
CN. A0
SG-5VRT5(COMMO.R)
0.75W 481
0.75W 479
0.75R 471
0.75WG 873
0.75G 874
0.75YG 875
0.75GR 487
0.75W 867
0.75RG 477
0.75W 866
0.75WR 484
0.75Y 485
0.75RY 478
0.75BY 498
0.75WL 483
0.75OL 482
0.85YL 486
0.75YB 488
BL 956
BL 957
0.85Y 476
0.85BY 496
PB 589
WR 501
GrR 504
BL 956
YR 553
PG 588
0.85BrY 575
0.85LgR 502
YR 552
PL 581
P 580
BrR 506
1.25GR 395
1.25GR 394
0.85BG 632
0.85BG 631
0.85BG 630
1.25B 732
1.25B 731
1.25B 730
117 118
0.85LY 402
0.85BG 427
1 2
1 2
0.75BY 498
(NEGA_CON-1:FRONT PUMP)
58X
90 91 92 93 94 95 96 97
82 83 84 85 86 87 88 89 114 115 116
98 99 100 101 102 103 104 105
0.75WB(5V)
0.75LY(OP-SIG)
PRESS. SENSOR
0.85WG 417
1 2 3
4 5 6
62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44
81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63
(BLUE TAPE)
0.85LY 407
SWP
106 107 108 109 110 111 112 113 119 120 121
B44
AMP HYBRID I/O

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6
43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
BG 652
2B 748
RW 558
531,532,567 890,900,901
CN. A1
0.85BY 421
OR 455
14
0.85PL 417
SWP
G 464
0.85Y 401
0.85YL 411
0.85LY 407
1 2 3
BrG 461
10
PRESS. SENSOR (P2)
SDL
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
3
GR 982
2
B 725
WR 555
5
BrW 260
2
B 728
GrR 893
1
PW 819
CN.23
CN.32
630,641,650,651,652,654,660,,661,670,681
R 225
1.25BG 600
1.25GR 394
BG 636
5
LR 250
3
2LR 060
BrR 506
AMP 040 MULTI LOCK
4 5
60B 799
0.75GR 396
1.25B 730
1
5
1.25B 701
B 702
710,711 713,715,725
B 722
4
1
YR 552
2LR 310
WR 541
GrR 504
1.25GR 394
2
3 5
4
49 50 51 52 53 54 55 56
57 58 59 60 61 62 63 64
CN. A0
58M
2 3 4
6 7 8
CN.21
1.25BG 600
B 702
1.25B 701
CN.9
1.25B 700
603,604
603,604,636
WR 541
2LR 310
0.85GrR 010
394,540
LgR 542
WR 391
461,501 502,504
506,552 895
0.85LR
LgR 503
0.85LgR 502
12
CN. 28
AMP NEW SCCS
0.85RY
BY 943
0.85GrG 437
B28
1 2
633,634,635,637
YG 942
0.85L 418
LY 435
0.75YB 488
B42
58X
1.25BG 600
M5
CN. 51
AMP 070 MULTI LOCK
11
18
0.85Y
BrY 432
4
6
0.85GL 413
1 2
255,256,413,415,425,501,589
WR 555
13
L 418
PW 255
1.25V 256
10
MOTOR-ACT (MODE)
BrY 432
0.75GR 396
0.85YG
YG 431
1.25BG 600
1.25B 701
LG 430
413,415,418,425,430,431,432,435,437,461,464,895
LY 435
0.75RL(GND)
12
0.85BG 660
400,410,411,412,417,420
YG 431
GrG 437
2B 700
630,670
LG 430
0.85YW 270
0.85LW
0.85LgB
0.85GR 896
(GND) 2B
K11
0.85Br
(COMP.POWER) 0.85WG
K10
K3
1.25LW 340
(MAIN POWER) 2WG
WR 535
0.85YB
0.85BR
0.85OR 386
0.85GR 567
27
(ILLUMINATION) 0.85RB
0.85OR 385
0.85GB
WR 980
14
GY 566
17
0.85GR 567
23
14
(RECIEVER DRYER) 0.85GW
0.85LgR
(WATER TEMP.SIG) 0.85BrW
0.85Y
WR 531
0.85GR 890
0.85YB
11
28
0.85LR
VR 524
LAMP(CAB)
LAMP (HOUSE,BOOM)
0.85VR 371
0.85RY
0.85YL
15
HORN
0.85VR 370
0.85LgW
VW 525
YR 560
0.85YR
7
16
0.85VR 900
10
0.85B
(LIMIT SW.DOOR) 0.85O
(LIMIT SW.WINDOW) 0.85YW
B 725
0.85YG
050,250,260,819
BY 561
LW 532
LgR 503
24
2WR 050
0.85GW
PL 562
13
0.85W
0.85GW 291
12
0.85G
0.85GW 290
0.85LW
060,503,893,982
WR 555
0.85GW
PW 563
290,370,385,896
12
CN. 12
29
SDL
0.85Br
1 2
0.85WL
1
2 3
4 5 6 7 8
CN. S0
0.85R
CN.36
BG 657
CN-A
CN.53
1 2 3 4
1
0.85GrR 010
3
WR 390
1.25LgR 540
4
1.25RW 220
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
2
0.85LY
CN. S9
CN. S7
1 2
3 4
M
CN. S4
0.85YL
0.85WG
2
3 5
4
BG 657
2BG 600
58X
418,430,431,432,434,435,437,455,464,580,581
11
CN.37
FUEL SENSOR
300,464,630,670,810,840,841,842,980,982
SWP
CN. 4
25
CN.31
2
3 5
4
0.85B 754
1 2 3 4
5 6 7 8
MEMORY
2Mbyte
0.85LgW
SUNLOAD SENSOR
0.85B 753
0.85B 754
CN.U6
FLASH
BW 565
2
3 5
4
17
0.75RY 478
1 2
RAM
2kbyte
13
WL 564
0.85B 753
R5
58X
I/O
0.85WL
0.85LgB
MOTOR-ACT (AIR-MIX)
M6
0.85WR
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
BrG 441
0.85RG
0.85WR
0.85BR
G 450
64
30
0.85BR
63
TRAVEL MODE
0.85YR
15
0.85RG
0.85BrR
0.85WG
ONE-TOUCH IDLE
0.85B
0.85WG
LG 430
2WG
16
26
0.85BR
62
UPPER PILOT
BrY 432
CN. S5
61
CN. S6
SWING PILOT
12 3 4 5
60
1 2 3 4 5
SPARE23(SW.)
M7
1 2 3 4 5
WG 448
0.85WG
22
B61
0.75BR 497
t C
B24
1 2
59
0.85BrR
0.85W
K6
0.85BW 420
AMP
WARNING CHG.
0.85G
18
20
K5
G 465
0.85WL 410
CN.D3
YL 451
K17
CN. S8
2R
17
21
19
B 775
0.85B 744
K2
0.75RW(5V)
0.75L(BP-SIG)
0.75GR 396
1 2
58
0.85OB
0.85GY
1
2 3
1
2
17
0.85R
BW 565
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2
0.85OB
1.25BG 600
P 592
PL 593
0.85O
15
14
16
1 2
3
16
BW 565
TO BEACON
B 775
58X
HYD.FAN REVERSE
0.85B 741
0.75GR 487
B1
1 2
GrG 437
BG 603
WL 564
SWP
VY 440
57
18
PW 563
BG 656
0.85WY 400
CN.T9
56
COOLANT
BG 603
13
0.75RG 477
2ND-OPTION LINE PILOT PRESS.
1 2
WORK MODE
X2
B 755
CN.H2
LY 435
0.85B 740
GrR 893
1 2
3 4
OG 442
55
B 711
58X
54
17
12
B22
SENSOR
11
Y7
CONT.
B 734
CN.H0
AUTO MODE
BREAKER PILOT
0.85GR 231
B 711
SWP
OR 455
15
0.85BY 941
CN.B8
VG 447
53
0.85BL 490
YR 552
WATER TEMP.
0.75BR(BT)
K11
K17
K30
K31
K32
K33
M1
M3
M4
M5
M6
M7
M8
M9
B50
VCC
PUMP
1 2
52
DEUTSCH
BEACON
L/M MODE
0.85BL 490
0.85GR 231
0.85YR 940
CN.H1
L 418
YG 431
0.85LG 480
WL 564
BG 656
SUMITOMO
HW090
0.85RB
51
0.85LY 470
PW 563
LAMP (BOOM) 2
BG 656
E2
24V 70W
G 464
CN.R0
2R
0.85L 480
PL 562
SWP
0.85B 744
0.85LY 470
11
G 464
1 2 3
0.85BrW
0.85BrR 897
VR 841
10
BG 656
LAMP (BOOM) 1
16
2LR 310
BrY 432
BG 652
VR 841
PL 562
CN.R1
2L
BLOWER-OFF RELAY
CN. 4
G 450
BG 656
G 464
B27
1 2
M8
0.85YW
0.85B 740
SWP
BLOWER MOTOR
30
CONDENSER FAN
0.75BW
1 2 3
0.85PL 581
0.85L
0.85B 744
BEACON
Y(VCC)
1 2
39
20
603,636
GLOW
19
BL 686
GND
1 2 3 4
5 6 7 8
9 10 11 12
CAN L
19
E2
24V 70W
G 450
BY 561
B25
CN.A8
0.85P 580
14
2L
0.85GrR 010
YR 560
0.75R 954
OB(GND)
15
AMP
29
2B
0.85BrR 890
BG 651
CN.B3
40
CAN H
0.85BrR 890
0.85GrR 010
BY 561
G(MRE) SENSOR
PRESS. SENSOR (P1)
1.25LgR 540
YR 560
18
0.75L 953
SWING PILOT PRESS.
0.75B
0.75G 955
0.75WL 483
PACKARD
CN.A7
BLOWER AMP
NO USE
0.85LB
CN. S1
48
0.85LB
0.75RB(WT)
1 2
3
A6
P6
VW
BW 688
1 2
OW 458
OG 459
18
BREAKER PILOT PRESS.
1 2
46
0.85OB
G 464
SPARE19(SW.)
(RED TAPE)
CONTROL PANEL
YG 431
LY 444
0.85GY
E1
24V 70W
WR 390
10
0.85LY
TRAVEL PILOT PRESS.
G 464
CN.D2
45
CN. S2
B26
SUMITOMO
HW090
SWING LOCK
CN. S3
CN.D1
WG 446
BG 650
SUMITOMO
HW090
BrR 530
44
0.85B 740
BG 636
LG 430
CN.D0
43
0.85B 741
1.25LgR 540
A9
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
ENG.STOP
SOFT/HARD
1 2
0.85LgR 891
0.75L 951
K7
K8
K10
B23
2ND-OPTION LINE PILOT PRESS.
LAMP (HOUSE)
E3
0.75G 950
B49
SUMITOMO
HW090
1 2
1 2
42
BG 655
090
CHECK
CONTROL AMP
BG 655
CN.B0
BrG 460
41
1
2
38
TEST
BG 655
HORN (LEFT)
24V,303Hz,115dB
B 754
LW(GND)
UPPER PILOT PRESS.
1
2
BREAKER MODE
24V 70W
0.75Br(COM-SIG)
14
TEMP. SENSOR
LY 435
HORN (RIGHT)
24V,333Hz 115dB
13
0.75G 491
FUEL LEAKAGE
LY 435
WR 390
B5
R4
BrG 461
CN-A
GrG 445
BG 655
TRAVEL ALARM
24V,107dB
CN.U7
37
LY 435
B81
0.85B 753
0.85BrR 897
CN.30
BG 655
LY 435
0.85LR 901
0.85BG 604
2
3 5
4
BrG 461
B81
K33
BG 655
G 464
1 2
HIGH DUMP
1.25RW 220
BG 655
0.85B 754
0.75W 481
BREAKER&CRUSHER PILOT PRESS.
0.85VR 900
L(5V)
Y9
(YELLOW TAPE)
SWP
YG 443
LY 435
G 464
CN-A
0.85BL 490
0.85BG 604
BrR 840
CN.F0
0.85L 480
B 713
11
LY 435
1 2
3 4
0.85LY 470
10
LY 435
0.85LR 901
12
SENSOR
B 767
H2
0.75R 471
0.75WR 484
SUMITOMO
DL090
CN.A3
B 713
BrG 461
PRESS. SENSOR
OIL PRESS.
1.25OW 300
B 752
B 752
MAIN
0.85BG 604
G 464
W 820
58X
36
W 820
COMMONRAIL
60B 798
GrG 445
830,840,842
BrR 840
3
4
GW 810
M6
CN.D4
BZ. STOP
B 767
0.85B 760
0.85BrR 890
14
EVA-SENSOR
THERMISTOR (INNER TEMP.)
1 2 3
4 5 6
GrG 445
AIR CONDITIONER
E52
B 710
LW 532
1.25RW 220
G 464
G 464
G 464
B 772
CN.B2
1 2
SUMITOMO
MT090
CN. 55
S21
32
35
CN.19
LW 532
WR 391
BrG 461
WG 448
WR 390
SDL
CN.61
SDL
B 716
0.85GR 231
0.85B
0.85L
1 2 3 4
1.25BG 600
0.85Y
VW 842
13
2ND OPT.PILOT
0.85B 742
BrR 840
BrR 840
2SPEED
1 2
12
34
OW 300
B 752
LAMP (CAB)2
0.85GR 892
090
VW 842
WG 448
B 711
33
24V 70W
1.25O 895
GW 810
1 2
BrG 460
VR 841
SPARE16(SW.)
RW 558
LAMP (CAB)1
VW
BrR 840
BOOM UP PILOT
BY 943
E3
BrG 460
VY 434
0.85YR 940
VR
BG 603
0.85VG 469
16
G 450
CN-A
YR 940
BrR 840
CN. 52
GrR 893
0.85B 743
BrG 460
3 2 1
SDL
CN. 50
15
YR 830
18
CN. 3
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
ONE TOUCH IDLE
1 2 3
4 5 6
GrR 893
0.85B
VR 240
17
GR 982
1.25B
GND
WR 980
14
TA GND
B 717
13
GR 982
YR 830
ST
LR 251
WR 980
20
VCC
OPTION
BrR 840
1.25O 300
090
ACC
ON
0.85LR 901
CN.M1
24
1 2
SWP
CN. 54
12
0.85GR 894
VR 240
S16
OFF
0.85LR 901
VW 842
CN.M0
26
ST
HEAT
ST
BrG 461
VR 841
1 2
19
GND
0.85BrR 890
OW 301
SWP
SERIAL INPUT
PL 584
ACC
11
19
20
ELE.FUEL PUMP
CN.G2
PW 583
G2
0.85GR 890
RW 558
0.75RL(VCC)
M9
OW 300
1.25O 895
0.85B 771
Y8
1 2
WR 571
25
G1
Br 556
X7
1.25O 300
240,448
ACC
B
VW 842
10
222,391,710,970,971,972,973
CONNECTION
ON
Br 556
1.25B 778
M20
090
22
HEAT
X6
VW 842
CN.C6
PROTECT
SERIAL OUTPUT
CAB SEAT
VR 841
BO 943
24V
1
2
LG 570
CN-A
SW. TO ACCESS
28
BrR 840
VR 841
CN.B5
20
OFF
BrR 840
GW
24V
KEY SWITCH
THROTTLE VOL.
SHUT OFF
1.25O 895
1
2
SG
PG 586
BP 587
CN-A
Rx
R3
GW 810
CN.Q2
P 585
21
OR 811
1
2
27
GW 810
GND
0.85GR
CN-A
Tx
12V OUT(BACKUP)
GR
B 714
S1
CN.Q0
23
S25
LIMIT SWITCH (GATE)
VW 842
YR 830
1
2 3
CN. 2
CN-A
5V
HORN SWITCH
VR 240
CN. 64
10V
58W
CN.60
0.85BY 729
YG 942
0.75R 876
B53
1 2 3
4 5 6
BATT.CHARGE
BG 605
0.85RW 282
0.85BY 941
0.75GY(W)
B52
CN.A5
16
B 713
0.85BrW 804
18
0.75GW(V)
SUMITOMO
DL090
LgR 542
SPARE12(CMP)
17
M14
1 2
BrW 804
090
GrG 445
12V OUT(MAIN)
CN.C5
0.85PL 417
BrR 543
B 777
1 2
0.85BL 490
LW 532
0.85LgW 803
SWP
5
12
BW 721
CN.C7
A GND
S15
2B 758
LgW 803
M3
WIPER MOTOR
OVER LOAD WARNING

KEY SW.
S51
WV 931
1.25O 331
GND
BY 941
0.75G 874
0.75YG 875
TO LUBLICATOR
0.85YW 802
OW 894
GND
U
G 464
GR
YG 942
0.75GB(U)
CONDENSER
BG 656
SWP
GW
1.25W 981
YW 802
U1
0.75LW(GND)
S52
1.25W 981
1 2 3
CN.P2
(YELLOW TAPE)
BrR 506
BG 606
1 2 3
4 5 6
BP 690
WIPER MOTOR(CCW)
0.85YR 281
MAGNET CLUTCH
435,461,464,895
VR
0.85RY 834
WR 980
300,840,841,842,980,982
SHUT OFF
0.85LW 801
603,604
STOP SIG.
12V
Y1
X15
SDL
CN-B
1
2
B 710
WR 391
R 222
LW 972
BL 973
CN.P6
PA
YW 970
VW
1 2
BY 971
B 702
DUAL SWITCH
LW 801
ACCESSORY SOCKET
REV. SIG.
SWING
630,641,660,661,670
10
1.25B
24V IN (BACKUP)
B 757
GR 982
758,759
0.85BrR
WINDOW LIMIT SW.
RADIO AM/FM STEREO 24V,2A
S64
0.85YR 283
BW
GR 983
090
CN.P1
POWER (24V) IN
3 2 1
6 5 4
14 13 12 11 10 9 8 7
CN-B
1
2
CN.P5
WASHER CONT.(-)
0.85B 765
0.85B 771
CN.24
91A
CN.P7
WV
R 223
0.75B 877
0.75WG 873
SENSOR
CN.G1
BG 606
AMP MIC
PG 588
BP 634
B 734
1 2 3
4 5 6
7 8 9 10 11 12 13
15
14
13
12
11
10
SDL
CN.25
1 2 3
0.85BG 637
1.25BG 600
BrR 543
16
(LIGHT GREEN)
1
B61
B81
B82
E1
E2
E3
E4
E51
E52
G1
G2
H1
H2
K2
K3
K5
K6
EGR POSITION SENSOR
4
8
12
16
20
WASHER CONT.(+)
24V IN (MAIN)
0.75WL(W)
3
7
11
15
19
GrR
2
6
10
14
18
13
VW 280
0.75WB(V)
0.75YB 872
1
5
9
13
17
WASHER SW. IN
A4
ANTENNA
B 702
Y6
HARD
0.85BrW 804
M15
CRANK ANGLE (MPU)
0.85B 756
SOFT
2R
2B
CN.A2
YR
WINDOW CONTROL
0.75WR(U)
SUMITOMO
DL040
LR
12
GND
B 702
0.75GB 871
1 2
11
WIPER SW.IN(CNT)
0.85LgW 803
24V
SWP
0.85LG 480
WIPER SW.IN(INT)
LW
R 223
R 223
12V OUTPUT
WIPER CONTROLER
BL
VW 280
CN.G0
YW
2B 748
(YELLOW TAPE)
DC/DC(24V/12V) CONVERTER
VW 280
RELIEF
2BG 600
YW
2B 700
2LR 915
2B 748
Y5
2B 700
BY
OW 546
2 STAGE
B 759
0.85B 763
GND (G2)
BY(SPK:R-)
(GREEN TAPE)
0.85B 771
LW
B 715
B752,772
0.85BrW 230
1
2
11
(BLUE TAPE)
LIGHTER 24V,5A
CN-A
0.85BW 420
0.85LY 470
BW 720
CN.Q1
E51
0.85YW 802
SDL
LW(SPK:L+)
YW(SPK:R+)
W1
S14
HYD.FAN SW.
1
WV 930
2B 748
(RED TAPE)
0.85B 764
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
BL
WIPER MOTOR(CW)
YG 451
OW 546
SWP
WV
0.75WB 870
B82
REFUEL PUMP
1 2 3
4 5 6
S13
BY 971
AUTO STOP ALARM
2GrR 330
CN.B1
10
0.85BrR 916
Y4
TRAVEL
1 2
0.85BG 604
BY
1 2
10
0.85L 412
YW 970
0.85B 761
2 STAGE
SWP
0.85YL 411
YW
B49
B50
B51
B52
B53
EGR MOTOR
S61
1 2 3
BG(B)
BY
X8
HBCV WARNING SWITCH
WG 448
B 725
0.85LW 801
CN.B6
1 2
P2 SIG
BrG 460
BL 973
CN.16
0.85WL 410
1
2 3
0.85WY 400
CN-A
S63
(RED TAPE)
CN. 65
A Vcc
P1 SIG
BP 690
Y3
CONTROL
SWP
15
IMMOBILIZER
BL
1
2 3
4 5 6 7
14
SPARE11(A/D)
0.85BG 621
B 715
PA
FUEL SENSOR
0.85BO 425
0.85GL 413
X9
B 713
CN.S4
SWP
BL(SPK:L-)
(KWP2000)
OPT.SW (MULTI)
BrR 840
LW 972
CN.70
13
0.85BG 621
WR 390
SUMITOMO
MT090
A GND
0.85VG 469
1
2 3
0.85OL 415
CN-A
CN. 63
THERMO SENSOR(O)
1
2 3
MEMORY CLEAR1
CN-A
CN. 62
0.85PG 598
LW
0.85BY 727
BG(B)
0.85BG 635
X23
VR 524
VR
OPT.SW (OPT.2SPEED)
WR
SDL
VW
CN.71
BP 690
B 711
CN.14
VR
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
JOINT
CONNECTOR
2 1
PB 589
BrR 840
SDL
VW
BG(B)
7
BG 620
VW 525
CN.U8
RS232C
BG
CN.P4
VR
PB 590
X24
0.85B 762
58X
BG 633
VW
0.85VW 800
2GrR 330
SWING BRAKE
CN.T4
B 710
Y2
LEVER
1 2
PG 586
BW
1 2
0.85GR 896
L 913
R1
LOCK
(PINK TAPE)
SWP
P 585
11
TECH2 CONNECTOR
X4
MEMORY CLEAR2
1.25B 700
GW 329
0.85B 749
(BLUE TAPE)
SUMITOMO
MT090 CN.U9
WR
1
2
VR 523
1 2 3
4 5 6
7 8 9 10 11 12 13 14
P5
LG 570
LIMIT SW. (F-WINDOW)

WR
WR 571
VR
SDL
CN. 10
RW 557
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
S54
13
YR 522
B 722
BG(B)
LR 521
WV 931
VW
12
YR
BW 721
VW
CN.P3
1
2 3
4 5 6 7 8
H1
LR
0.85GR
35
GrR 520
0.85B 760
B47
B48
5BW
1 2 3 4
5 6 7 8
BZ.
GY 566
14
SUMITOMO
DL090
S53
0.85BG 604
BG 664
24V
VR 912
24V
0.85GR 831
M1
1 4 2
5
3
CN.B7
25
GrR
24V,10W
LIMIT SW. (DOOR)
HOURMETER
0.85BrR 360
1 4 2
5
3
AUTO/MANUAL SELECT SW.
A/C CONT.
5V 4.7k
M4
SWP
34
LCD
WR
0.85BrR
BG 603
0.85BG 645
CN.C8
INCR
GND
2BG 600
BG 636
BW 720
330,546
1.25BG 602
GLOW PLUG
1 2
33
WASHER
ROOM LAMP
E4
0.85B 745
SUMITOMO
090
DECR
WIPER
0.85B 745
WV 930
CN.B9
26
1.25BG
0.85B 704
WASHER
8R 100
CN.U5
ISC2
22
0.85B 704
3LR 060
010,540,541,543
1 2 3
24
BrW
SDL
ISC3
21
PUMP STOP
REFUEL PUMP
CN.S3
602,603,604,636,645,664
CN.15
36
1.25BG 602
M5
B42
B43
B44
B45
58X
BrW 804
SWITCHED DROP
20
2B 700
24V 7.0kw
1 2
31
23
1.25BG
1.25O 300
M10
K31
K30
BG 670
1 2
SWING SHUT-OFF
VARIABLE ISC
GND
1.25B 700
BG 651
58X
OR 811
WV 813
VR
1.25O 300
1.25BG 600
5Y 004
CN.T5
30
20
20
1.25GR 394
STARTER MOTOR
1 2
29
WL 812
WINDOW L/SW.
2GrR 330
B27
B28
M6
3LR 060
M8
(BLUE TAPE)
CN.E5
CUSHION
32
19
BrW 545
FPC
HIGH DUMP
SPARE1(PNP)
SPARE2(PNP)
BrW
0.5mF
BG 650
CN.S1
S12
19
ALTERNATOR
GND
B 734
B 734
YR
P4
LgW 803
VR 523
2Gr 330
8R 100
60R 001
3LR 060
1.25GR 394
5Y 004
B25
B26
SUMITOMO
MT090
CN.T6
LW 801
YR 522
18
1 2
3
28
17
VR
WIPER(CNT)
WORKING LAMP
BG 641
58X
2 STAGE TRAVEL
YR
1.25Br 030
CN.T8
VW 800
WIPER(CNT)
WINDOW L/SW.
LR
B 759
B24
8R 100
CN.E4
RW 558
27
LR 521
1.25BrR 543
B 779
CN.E3
22
SWING BRAKE
GrR 520
16
18
ALTERNATOR
G1
CN.E1
HYD.FAN REVERSE
15
LR
1.25Br 030
R
L
CN.A4
S11
WR 501
WIPER(INT)
ENG.STOP
S10
21
GrR
17
SWING LOCK
S9
YG 942
WASHER
WIPER(INT)
16
12V
GrR
BZ STOP
1
CN-A
CN.C0
2GrR 330
15
S7
12V
OW 546
WASHER
PANEL;SWITCH (R)
5V
17 18 19 20 21 22
23 24 25 26 27 28
1
2
3LR 060
CN.1
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
SDL
CN.22
1.25YR 208
ENG.STOP
CN. 3
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
2LR 060
1K
CN. 2
BrR 544
1.25YR 208
BrR 530
V REF
CN. 1
BrW 545
WR 531
14
BrG 460
8kbyte
91-A
13
BrR
0.85BrY 575
E2PROM
Br 556
WR
ENG.STOP
W 820
TRAVEL PILOT
CN.13
WORKING LAMP
BrR
19
50
SDL
WR
14
5WR 003
B
0.85GrR 010
B 759
772,830
13
WARNING BUZZER
SPARE21(SW.)
OG 442
WR 541
GND (G1)
ENG.STOP
GW 810
49
OG
RELAY SAFETY
1.25G 020
M4
M8
WORKING LAMP
18
AIR CLEANER
BW 720
1.25BG 601
17
CAN GND
WV 930
18
1.25BG 600
BEACON
CAN
17
BW 720
1.25WR 209
REFUEL PUMP
I/O
WV 930
S8
47
0.85B 745
2B 700
1.25WR 209
OW 546
SPARE20(SW.)
SPARE24(SW.)
0.85BW 420
LY 444
P3
31
16
12
YW 802
IMMOBILIZER
OVER LOAD
0.85BW 420
LY
BO 943
1/4
0.85BG 645
2BG 600
SWING LOCK
GND
575,588,589,592,593
COUNTER
0.85PL 417
LY
TA INPUT
15
12
RXD
0.85PL 417
PL 584
633,634,635
SCI
14
0.85L 412
PW 583
2 STAGE RELIEF
TXD
0.85L 412
11
HYD.FAN MOTOR
RECIEVER
0.85YL 411
PL
15
SPARE13(CMP)
13
TXD
(BEACON)
B 734
RXD
0.85YL 411
PL
BP 587
SCI
12
0.85WL 410
11
HYD.FAN MOTOR
RS232C
DRIVER &
0.85WL 410
TXD
SWING LOCK
CN.6
TXD
0.85WY 400
YG 443
16
5V
0.85VR 900
11
5V
A/D
10 bit
10
10
NO USE
SIG THROTTLE VOL
0.85VR 900
0.85WY 400
PW
BY 941
A GND
0.85VW 800
YG
5V THROTTLE
RXD
PUMP RET
N1 SIG
VW 800
BZ STOP
1.25W 325
100
OW 546
PW
24VB
1K
W 820
YG
PROTECT
24V
YR 940
NO USE
W 820
10
14
PROTECT
0.85GR 831
RXD
S6
1
2 3
4 5 6 7 8
13
AUTO MODE
3 4
1 2
5 6 7 8 9
GND
OG
CN.11
GND
0.85GrR 010
CN.E2
PWM
11
GR 831
BZ STOP
PUMP OUT
PWM
D/A
8 bit
GND
AUTO MODE
0.85GrR 010
CN.E0
SINGLE CHIP CPU
GND
VG 447
1.25BrR 543
1
2
CN.P8
GND
VG
WR 541
K8
M4
B 767
BEACON
VG
1 2
GND
WG 446
SDL
1.25W 321
WG
CN.35
WR 541
BrR 543
OW 546
GR 831
BEACON
91A
12
VY 440
SOFT/HARD
CN.P9
1.25W 320
BrG 441
WG
1 2 3
CONTROL 24V
VY
B 722
SOFT/HARD
SDL
CN.P0
1.25LgR 350
BrG
WORK MODE
VY
RW 557
YR 830
WORK MODE
1.25LgR 540
0.85BG 660
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
BrG
(SOFT/HARD)
CN.26
1 2 3 4 5 6
1.25RW 220
R 222
R 223
206,208,209
KEY SW.
F12
20A
BACK UP
R 221
10A
F11
MAIN
20A
F1
0.85GR 231
0.85BrW 230
1.25R 206
M10
1.25G 020
1.25LgR 351
R 221
S5
10
2
3 5
4
G2
M8
1.25LgR 540
58Y
POWER 24V
5V
B+
TRAVEL MODE
M8
M10
REGULATOR
020,030
60R 001
60R 201
M10
IC
1.25LR 204
020,030
CN.A6
FILTER
1.25W 322
60R 200
1.25LgR 540
5R 002
1.25RW 202
1.25R 206
24V 50A
M5
1
2 3
A1
1.25WR 209
K7
RELAY BATTERY
ALTERNATOR
E
5B 797
CN-A
CN.S2
COMPUTER
CN.5
HYDRAULIC FAN
1
2
3
4
(BLUE TAPE)
1.25GR 205
1
2
B+
TRAVEL MODE
WL 812
WV 813
OW 458
OG 459
1.25YR 208
F22
F27
1
2 3
S4 AUTO MODE
1.25W
IGN
CN-A
CN.C2
CN-A
1.25W
CN-A
CN.C3
CN.B4
IGN
1
2
CN-A
AMP 040 MULTI LOCK
K32
ILLUMINATION
S3 WORK MODE
1
2
CN-A
CN.C4
CN.C1
CN.T3
TRAVEL MODE
CONTROL CONNECTOR
SDL
17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36
PWB
ADDITIONAL
1 2 3 4
S2
F25
M10
CN.28
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
PANEL;SWITCH (L)
1.25RY 225
812,813,458,459
645,745
MONITOR DISPLAY ASSY
P2
1.25R 206
592,593,598
CN.6
BrW 545
0.85BG 637
CN.5
2
4
1.25RY 225
P1
BrR 544
206,208,209
2LR 310
CIGAR LIGHTER
CAB SEAT
F20
15A
LOCK LEVER
(GATE)
1.25V 256
VR 240
10A
F4
ELEC.FUEL PUMP
20A
F8
AIR COND. FAN

0.85YW 270
BrW 260
10A
F5
AIR COND.
COMPRESSOR
F14
5A
DC/DC
CONVERTER
F17
VW 280
PW 255
0.85GW 290
1.25W 322
1.25W 325
10A
HORN CTWT
REMOVAL
F19
15A
COMPUTER
CONTROL
1.25W 320
LR 250
5A
F2
10A
F6
BEACON
ENGINE PRE-HEAT
30A
F9
1.25O 300
2WR 050
20A
F10 OPTION LINE
LUBRICATOR
FUEL FEED PUMP

30A
F7
1.25LW 340
2Gr 330
20A
F13 AIR COND.
COMPUTER POWER
20A
F3
1.25LgR 350
15A
F18 WIPER,WASHER
0.85VR 370
0.85B 704
0.85OR 375
0.85PG 598
PL 593
0.85RY 225
1.25R 206
1
2
58L
CN.C5
1 2
CN.Z2
1.25WR 209
8R 207
1
2
58X
DEUTSCH
HD14
P 592
J
H
0.85BrR 360
G H J
1.25YR 208
1
2
58L
FUSE A (20A)
FUSE B (20A)
60A
F24
CN.C9
A B C D E F
0.85OR 385
D
A
0.85BG 637
E
F
15A
X3
15A
F16 LAMP(CAB)
X5
F15 LAMP (HOUSE,BOOM)
3R 213
58L
3R 211
3R 212
OPTIONAL
POWER
F23
8R 207
8R 100
8R 207
R 225
F21
8R 207
CN.20
5R 210
EST CONNECTOR
A1
A2
A4
A6
A9
B1
B2
B3
B5
B6
B21
B22
B23
Y15
(RED TAPE)
FUSE 20A ; ENGINE CONTROLLER

FUSE 5A ; COMPUTER CONTROL INSTRUMENT PANEL AND
DIAGNOSTIC TEST SOCKET
FUSE 20A ; COMPUTER POWER
FUSE 10A ; HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH
FUSE 10A ; AIR CONDITIONER CONDENSER FAN
FUSE 10A ; ROTARY LIGHT
FUSE 30A ; FUEL FILLER PUMP
FUSE 20A ; FUEL FEED PUMP
FUSE 30A ; GLOW PLUG
FUSE 20A ; LUBRICATOR (OPTION) CONNECTOR
FUSE 10A ; BACK-UP
FUSE 20A ; KEY SWITCH
FUSE 20A ; HEATER / AIR CONDITIONER
FUSE 5A ; AIR CONDITIONER COMPRESSOR
FUSE 15A ; WORKING LIGHT (UPPERSTRUCTURE/ATTACHMENT)
FUSE 15A ; WORKING LIGHT (CAB) AND OPTION CONNECTOR
FUSE 10A ; DC-DC (24V-12V) CONVERTER
FUSE 15A ; WIPER AND WASHER
FUSE 15A ; HORN
FUSE 15A ; CIGARETTE LIGHTER AND CAB SEAT COMPRESSOR
ADJUSTMENT
FUSE BOX
FUSE 20A ; MAIN FUSE FOR F11 AND F12 CIRCUITS
FUSE 65A ; MAIN FUSE FOR F3 TO F10 AND F13 TO F20 CIRCUITS
FUSE 20A ; MAIN FUSE FOR F2 CIRCUIT
FUSE 20A ; MAIN FUSE FOR F1CIRCUITS
FUSE 60A ; SAFETY RELAY
Y7
Y8
Y9
Y12
Y13
Y14
Y15
Y31
Y32
Y33
Y34
COMPUTER
ENGINE CONTROLLER
WIPER CONTROLLER
BLOWER CONTROLLER
AIR CONDITIONER CONTROLLER
COOLANT TEMPERATURE SENSOR
HYDRAULIC OIL TEMPERATURE SENSOR
FUEL TEMPERATURE SENSOR
EVA SENSOR
AIR INTAKE TEMPERATURE SENSOR
ENGINE OIL PRESSURE SWITCH
SWING PILOT PRESSURE SWITCH
BREAKER / CRUSHER PILOT PRESSURE
SWITCH
SECOND OPTION PILOT CIRCUIT 2
PRESSURE SWITCH
BREAKER PILOT PRESSURE SWITCH
UPPER PILOT PRESSURE SWITCH
(YELLOW BAND)
TRAVEL PILOT PRESSURE SWITCH
SECOND OPTION PILOT CIRCUIT 1
PRESSURE SWITCH
PRESSURE SENSOR (NEGA-CONT)
(BLUE BAND)
OVERLOAD INDICATOR PRESSURE
SWITCH (EUROPE)
BOOST PRESSURE SENSOR
AMBIENT AIR (BAROMETRIC) PRESSURE
SENSOR
CRANKSHAFT POSITION SENSOR
CAMSHAFT POSITION SENSOR
BOOST TEMPERATURE SENSOR
COMMON RAIL PRESSURE SENSOR
EXHAUST GAS RECIRCULATION VALVE
POSITION SENSOR
SUNLOAD SENSOR
HORN
REFUEL PUMP STOP ALARM
WORKING LIGHT (UPPERSTRUCTURE)
WORKING LIGHT (ATTACHMENT)
WORKING LIGHT (CAB)
CAB LIGHT
CIGARETTE LIGHTER
AIR CONDITIONER
BATTERY
ALTERNATOR
AUDIBLE WARNING DEVICE
TRAVEL ALARM
RELAY-GLOW PLUG
RELAY-HORN
RELAY-ROTARY LIGHT
RELAY-AIR CONDITIONER CONDENSER
FAN
RELAY BATTERY
RELAY SAFETY
RELAY-WORKING LIGHT
(UPPERSTRUCTURE/ATTACHMENT)
RELAY-WORKING LIGHT (CAB)
BLOWER OFF RELAY
REFUEL PUMP RELAY
REFUEL PUMP STOP RELAY
RELAY, HYDRAULIC FAN
MAIN RELAY
STARTER MOTOR
WIPER MOTOR
WASHER MOTOR
MOTOR (AIR CHANGING)
AIR VENT DIRECTION CONTROL MOTOR
MOTOR ACT (AIR-MIX)
BLOWER MOTOR
AIR CONDITIONER CONDENSER FAN
MOTOR
FUEL FEED PUMP MOTOR
EXHAUST GAS RECIRCULATION MOTOR
ELECTRIC FUEL PUMP
INSTRUMENT PANEL
SWITCH PANEL (LEFT-HAND)
SWITCH PANEL (RIGHT-HAND)
MONITOR DISPLAY
HOURMETER
AIR CONDITIONER CONTROL PANEL
GLOW PLUG
THROTTLE VOLUME
THERMISTOR INNER TEMPERATURE
FUEL SENSOR
KEY SWITCH
TRAVEL MODE SWITCH
WORK MODE SWITCH
AUTO MODE SWITCH
CUSHION CONTROL SWITCH
ROTARY LIGHT SWITCH
AUDIBLE ALARM CUT OUT SWITCH
SWING BRAKE SWITCH
ENGINE EMERGENCY STOP SWITCH
WORKING LIGHT SWITCH
WIPER SWITCH
WASHER SWITCH
OVERLOAD SWITCH
BREAKER / CRUSHER SWITCH
HORN SWITCH
ONE TOUCH IDLE
COUNTERWEIGHT REMOVAL MAIN SWITCH
COUNTERWEIGHT RAISING/ LOWERING
SWITCH
COUNTERWEIGHT ARM
RAISING/LOWERING SWITCH
OPTIONAL SWITCH (RIGHT)
OPTIONAL SWITCH (LEFT)
HYDRAULIC FUNCTION CANCELLATION
LEVER SWITCH
AIR CONDITIONING COMPRESSOR
CLUTCH SWITCH
DOOR LIMIT SWITCH
FRONT WINDOW LIMIT SWITCH
RESERVE TANK LOW SWITCH
REFUEL PUMP SWITCH
AIR CLEANER SENSOR
DOUBLE ACTING SWITCH (OPTIONAL)
COOLING HYDRAULIC MOTOR SWITCH
DC-DC (24V-12V) CONVERTER
ANTENNA
ROTARY LIGHT CONNECTOR
OPTIONAL POWER CONNECTOR
ENGINE TEST POINT CONNECTOR
CONTROLLER TEST POINT CONNECTOR
CAB SEATCOMPRESSOR MOTOR
CONNECTOR
LUBRICATOR CONNECTOR
RADIO CONNECTOR
ANTI-THEFT SYSTEM CONNECTOR
ACCESSORY SOCKET
CLEAR MEMORY 1
CLEAR MEMORY 2
SWING PILOT SHUT-OFF SOLENOID VALVE
(GREEN BAND)
PILOT PRESSURE SOLENOID VALVE
(BLUE BAND)
SWING BRAKE SOLENOID VALVE
(PINK BAND)
2 STAGE TRAVEL SOLENOID VALVE
(RED BAND)
POWER-UP SOLENOID VALVE
(YELLOW BAND)
CUSHION CONTROL SOLENOID VALVE
(LIGHT GREEN BAND)
MAIN PUMP PROPORTIONAL SOLENOID
AIR CONDITIONER MAGNET CLUTCH
CRUSHER/BREAKER OPTION TWO FLOW
SOLENOID VALVE
COUNTERWEIGHT RAISING SOLENOID
VALVE
COUNTERWEIGHT LOWERING
SOLENOID VALVE
COUNTERWEIGHT ARM RAISING
SOLENOID VALVE
COUNTERWEIGHT ARM LOWERING
SOLENOID VALVE
COOLING HYDRAULIC MOTOR SOLENOID
VALVE
PROPORTIONAL SOLENOID FOR COOLING
HYDRAULIC MOTOR
SUPPLY PUMP VALVE (PCV1)
SUPPLY PUMP VALVE (PCV2)
CN. A1
TABLE OF COLOR SYMBOLS
5B 796
M6
FLOOR
M6
PLATFORM
SYMBOL
COLOR
SYMBOL
COLOR
BLACK
RED
WHITE
YELLOW
Br
BROWN
Lg
LIGHT GREEN
PINK
Sb
SKY BLUE
VIOLET
BLUE
GREEN
Gr
GRAY
ORANGE
NOTE : "BR" INDICATES BLACK CABLE WITH RED STRIPE.
LEGENDE
CONNECTED
NOT CONNECTED
CONNECTOR (MALE)
BOOT GROUND
CABLE GROUND
SINGLE WIRE CONNECTOR
HARNESS
INSULATION AGAINST MAGNETISM
CN.
CONNECTOR NUMBER
SWP
CONNECTOR'S NAME
CONNECTOR (FEMALE)
60 B 001
CIRCUIT NUMBER
COLOR
AREA
CX460 EXCAVATOR
ELECTRICAL SCHEMATIC - 87574470A

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CX460 TIER 3 CRAWLER EXCAVATOR

* Consult the Engine Service Manual

Copyright 2006 CNH France S.A.

Clean all metal parts except bearings, in a suitable

Check all gears for wear and damage. Replace gears

Oil seals, O-rings and gaskets

This symbol means ATTENTION! BECOME ALERT! YOUR

To prevent injury always follow the Warning, Caution

WARNING: Before starting engine, study

WARNING: If you wear clothing that is too

WARNING: When working in the area of the

WARNING: When doing checks and tests

WARNING: When putting the hydraulic

WARNING: Read the operators manual to

WARNING: Operate the machine and

WARNING: This is a one man machine, no

WARNING: When servicing or repairing the

WARNING: Some components of this

WARNING: Engine exhaust fumes can

WARNING: When the battery electrolyte is

WARNING: Use insulated gloves or mittens

WARNING: Lower all attachments to the

WARNING: Pin sized and smaller streams

WARNING: When removing hardened pins

WARNING: When using a hammer to

WARNING: Use suitable floor (service)

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Cap Screw Name Size (Size)

Copyright 2007 CNH France S.A.

TYPE, SERIAL NUMBER

TYPE, SERIAL NUMBER

(1) Type .......................................................................................................................................................................

Serial numbers of the components

FLUIDS AND LUBRICANTS

Transmission component oil

Oil viscosity / Oil range

1) With mineral base

Engine fuel, maintenance of fuel filters and fuel storage

JIS (Japanese Industrial Standard)

DIN (Deutsche Industrie Normen)

SAE (Society of Automotive Engineers)

Maintenance of fuel filters

Plastic and resin parts

Complete machine dimensions

Main body dimensions

Capacity of coolant and lubricants

Hydraulic oil filter

Engine oil pressure*

24V, 70W (x1)

24V, 70W (x1)

24V, 70W (x2)

24V, 10W (x1)

Horn: electric horn (x2)

Travel lower body

Arm (dipper) length

Maximum digging radius

Maximum digging radius at ground line

Maximum digging depth

Maximum vertical straight wall digging depth

Maximum reach height

Maximum dump height