Page 1

REPAIR MANUAL

CX135SR

9-40641 1 14/12/2004


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

A B D E F H J

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INTRODUCTION

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

3

CX135SR

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

4

CX135SR

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

6

CX135SR

Torque ( - A.90.A.10)

7

CX135SR

Torque ( - A.90.A.10)

8

CX135SR

Dimension ( - A.92.A.30)

11

CX135SR

Weight ( - A.92.A.40)

14

CX135SR

Consumables ( - A.92.A.55)

15

CX135SR

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

18

CX135SR

Product identication ( - A.80.A.10)

20

CX135SR WE

Product identication ( - A.80.A.10)

21

CX135SR NA

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INTRODUCTION

Foreword ( - A.10.A.40) CX135SR

INTRODUCTION TO THE REPAIR MANUAL This manual has been designed so that in the near future it can be made available on CD and in a database via a computer network. This will allow fast and targeted search and navigation between the various information modules.

Information search

CRIL03J033E01

1

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

The function and information types are codied and appear in parentheses after the title and separated by a dash: (1) Function (2) Information type.

Only the rst letter (A) and the rst number (B) of the function need to be used for the information search. The rst letter (A) corresponds to the sections of the repair manual. The rst number (B) corresponds to the chapters of the repair manual. The rst part of the (A.B) code is reected in the page numbering. THE REST OF THE CODING IS NOT LISTED IN ALPHA-NUMERIC ORDER IN THIS MANUAL.

You will nd a table of contents at the beginning and end of each section and chapter. You will nd an alphabetical index at the end of each chapter.

Therefore it is the rst part of the (A.B) coding, then the tables of contents and index (page numbers) which will allow you to quickly nd the information you are looking for.

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INTRODUCTION

Safety rules ( - A.50.A.10) CX135SR

CAUTION M171C - THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY. ATTENTION: To avoid injury, always observe the Safety Notices, CAUTION and ATTENTION, contained in this section and throughout the manual. Place a “Do not start the machine” warning notice on the starter switch key before all maintenance or repair operations.

CAUTION M489 - Read the operators manual to familiarize yourself with the correct control functions.

CAUTION M490 - Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury.

CAUTION M265A - A frequent cause of personal injury or death is persons falling off and being run over. Do not permit anyone to ride on the machine.

CAUTION SB055 - Before starting engine, study operators manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operation. It is your responsibility to understand and follow manufacturers instructions on machine operation, service, and to observe pertinent laws and regulation. Operators and service manuals can be obtained from your dealer. ATTENTION: You risk injury if you wear loose clothing or if you do not use safety equipment for your work. Always wear clothes which are unlikely to become caught in the machinery. Other safety equipment may be required, in particular: hard hat, safety boots, ear protectors, safety goggles or mask, thick gloves and reective clothing.

CAUTION M124A - Rotating machine parts, stay clear, keep shields installed to help protect from clothing entanglement and injury. Wear close-tted clothing.

CAUTION SB071 - Rotating fan and belts: Contact will cause injury. Keep clear. ATTENTION: Follow the procedures exactly when carrying out checks or inspections on the vehicle’s hydraulic systems. DO NOT CHANGE the procedures. ATTENTION: Before running the hydraulic cylinders in this vehicle through the cycles necessary for checking their functioning or for draining a circuit, warn people nearby to move away.

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INTRODUCTION

CAUTION SM121A - Always wear heat protective gloves to prevent burning your hands when handling heated parts.

CAUTION M132B - Lower or block elevated implements and other attachments before servicing or when leaving the equipment.

CAUTION R149C - Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting uid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking uid, see your doctor immediately. ATTENTION: To remove a hardened pin, such as a pivot pin, or a hardened shaft, use a soft-headed hammer (brass or bronze) or a brass or bronze peg and a steel-headed hammer.

CAUTION M428 - Always wear safety glasses when using a drill, hammer, saw, or other tools that may cause chips to y. ATTENTION: Use suitable servicing jacks or a chain hoist for raising the wheels or tracks. Always chock the vehicle in place with suitable safety supports. ATTENTION: When carrying out maintenance or repair operations on the vehicle, keep the workshop oor, the driving position and the steps free from oil, water, grease, tools, etc... Use an oil absorbent material and/or workshop cloths as necessary. Always use sound methods. ATTENTION: Some parts of this vehicle are very heavy. Use lifting devices or additional assistance recommended in the Operator’s Manual.

CAUTION M532 - Do not operate the engine in a closed building. Proper ventilation is required under all circumstances.

CAUTION M503 - When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2), you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

CAUTION M244A - BATTERIES CONTAIN ACID AND EXPLOSIVE GAS. EXPLOSION CAN RESULT FROM SPARKS, FLAMES, OR WRONG CABLE CONNECTIONS. TO CONNECT JUMPER CABLES OR CHARGER, SEE MANUAL(S) FOR THE CORRECT PROCEDURE. FAILURE TO FOLLOW THE ABOVE INSTRUCTIONS CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH.

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INTRODUCTION

Basic instructions ( - A.90.A.05) CX135SR

GENERAL Cleaning Clean all metal parts except the bearings with white spirit or steam. Do not use caustic soda for steam cleaning. After each cleaning, dry and oil all parts. Clean the oil ducts with compressed air. Clean the bearings with parafn, then dry them completely and lubricate them.

Inspection Check all the parts when they are disassembled. Replace all parts that show signs of wear or damage. Supercial scratches and grooves can be removed with an oil stone or with a cloth dipped in red oxide. A complete visual inspection is necessary to detect wear and pitting, and replacing parts as soon as it becomes necessary will help to avoid premature breakdowns.

Bearings Check that the bearings turn freely. Replace them if their adjustment is too free or if their functioning is irregular. Wash the bearings with a good solvent or parafn and allow them to air dry. DO NOT DRY THE BEARINGS WITH COMPRESSED AIR.

Needle bearings Before pushing needle bearings into a cylinder bore, always remove all metallic projections from the bore and its edges. Before pushing in bearings with a press, coat the inside and edges of the bearings with Vaseline.

Gears Check all the gears and ensure that they do not show any signs of wear or damage. Replace the worn out or damaged gears.

Gaskets, O-rings and at seals Always install new gaskets, O-rings, and at seals. Coat the gaskets and O-rings with Vaseline.

Shaft Check all shafts showing wear or damage. Enusre that the surface of a shaft carrying a bearing or gasket is not damaged.

Spare parts Always use CASE spare parts. To order these, refer to the Spare Parts Catalogue and indicate the correct reference number of the CASE spare parts. Breakdowns caused by the use of parts other than CASE spare parts are not covered by the warranty.

Lubrication Use only the oils and lubricants specied in the Operator’s Manual or the Service Manual. Breakdowns caused by the use of oils and lubricants not specically listed are not covered by the warranty.

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INTRODUCTION

Torque ( - A.90.A.10) CX135SR

STANDARD TIGHTENING TORQUE Order of tightening nuts and cap screws. Tighten alternately so that torque remains uniform. Cap screws which are tted with Loctite (look for traces of a white residue on the thread after removal), must be cleaned with a thin oil or a suitable solvent, then dried. Add two or three drops of Loctite to the cap screw thread, then t the screw.

CRIL03H012E01

1

The numbers in the diagrams represent the order of tightening.

Tightening torque Where there are no special instructions, tighten cap nuts screws to the torques given in the table below. Standard torque setting table. Designation of cap screws (dimensions) Cap screw Spanner in mm Torque setting in Nm Wrench in mm Socket head screw Torque setting in Nm

M6

M8

M10

M12

M14

M16

M18

M20

10 6.9

13 19.6

17 39.2

19 58.8

22 98.1

24 157.2

27 196

30 274

5 8.8

6 21.6

8 42.1

10 78.4

12 117.6

14 176.4

14 245

17 343

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INTRODUCTION

Torque ( - A.90.A.10) CX135SR

SPECIAL TORQUE SETTINGS No.

Wrench Tightening torque Screw in mm diameter Travel motor and reduction gear assembly M16 24 267 - 312 Nm (1)* M16 24 267 - 312 Nm (2)* Sprocket Idler wheel M16 24 267 - 312 Nm (3)* Upper roller M16 24 267 - 312 Nm (4)* Lower roller M16 24 267 - 312 Nm (5)* M16 24 267 - 312 Nm (6) Shoe M30 46 1060 - 1235 Nm (7) Counterweight M16 24 267 - 312 Nm (8) Turntable (chassis) M16 24 267 - 312 Nm (9) Turntable (upperstructure) M16 24 267 - 312 Nm (10)* Swing motor and reduction gear assembly Engine M16 24 265 - 313 Nm (11)* Engine mounts M10 17 64 - 74 Nm (12)* Radiator M12 19 88 - 111 Nm (13) Hydraulic pump M10 17 64 - 74 Nm (14)* M12 Hex 88 - 111 Nm Hydraulic reservoir M16 24 232 - 276 Nm (15)* Fuel tank M16 24 232 - 276 Nm (16)* M16 24 267 - 312 Nm (17)* Control valve Hydraulic swivel M12 19 109 - 127 Nm (18)* M16 24 78 - 80 Nm (19) Cab Batteries M10 17 20 - 29 Nm (20) Use Loctite 262 or an equivalent on mounting screws for those components marked with an asterisk (*). Component

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INTRODUCTION

CRIL03L001H01

1

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INTRODUCTION

CRIL03L002H01

2

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INTRODUCTION

Dimension ( - A.92.A.30) CX135SR

Machine ď€ tted with monoblock boom

CRIL03L003G01

Item (A) (D) (G) (J) (M) (Q)

Dippers 2.39 m 2.75 m 1.75 m 1.48 m 1.99 m 0.43 m 1.17 m

2.85 m 2.60 m

Item (B) (E) (H) (K) (N)

1

Dippers 2.39 m 2.85 m 2.75 m 2.41 m 3.51 m 0.60 m 5.49 m 5.46 m

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Item (C) (F) (I) (L) (P)

Dippers 2.39 m 7.24 m 0.88 m 2.78 m 2.59 m 1.24 m

2.85 m 7.23 m


INTRODUCTION

Machine ď€ tted with monoblock boom and dozer blade

CRIL03L004G01

Item (A) (D) (G) (J) (M) (Q)

Dippers 2.39 m 2.75 m 2.26 m 1.48 m 1.99 m 0.43 m 1.17 m

2.85 m 2.60 m

Item (B) (E) (H) (K) (N) (R)

2

Dippers 2.39 m 2.85 m 2.75 m 2.41 m 3.51 m 0.60 m 5.49 m 5.46 m 2.49 m

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Item (C) (F) (I) (L) (P) (S)

Dippers 2.39 m 7.75 m 0.88 m 2.78 m 2.59 m 1.24 m 0.57 m

2.85 m 7.72 m


INTRODUCTION

Machine ď€ tted with backhoe-offset boom and dozer blade

CRIL03L005G01

(A1) (D) (H) (L) (P) (T)

3.54 2.26 3.51 2.59 1.24 1.15

m m m m m m

(A2) (E) (I) (M) (Q) (U)

2.87 2.41 2.78 0.43 1.17 1.18

m m m m m m

3

Dippers 2.11 (B) (F) (J) (N1) (R) (V)

m 2.75 0.88 1.99 5.27 2.49 0.21

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m m m m m m

(C) (G) (K) (N2) (S)

7.47 1.48 0.60 5.20 0.57

m m m m m


INTRODUCTION

Weight ( - A.92.A.40) CX135SR

Weight of machine Weight

Conď€ guration

With 600 mm track pads, monobloc boom, 2.40 m dipper, 380 kg backhoe bucket, 13200 kg operator and full fuel tank With 600 mm track pads, monobloc boom, 2.40 m dipper, 380 kg backhoe bucket, 14 100 kg operator and full fuel tank With 600 mm track pads, backhoe-offset boom, 2.10 m dipper, 380 kg backhoe 14 200 kg bucket, dozer blade, operator and full fuel tank

Ground pressure 0.36 bar 0.38 bar 0.38 bar

Weight of components Mono boom

Components

Engine Hydraulic pump Attachment control valve Swing motor and reduction gear assembly Travel motor and reduction gear assembly Boom cylinder Dipper cylinder Bucket cylinder Dozer blade cylinder Offset backhoe boom cylinder Counterweight Cab Turntable Upperstructure assembly Hydraulic swivel Undercarriage assembly Machine without attachment Attachment Boom assembly Dipper assembly Dozer blade Radiator and oil-cooler assembly Fuel tank Hydraulic reservoir Idler wheel Upper roller Lower roller Tension shock absorber Track 500 mm Track 600 mm Track 700 mm

363 kg 91 kg 140 kg 103 kg 144 kg 121 kg 157 kg 93 kg

Mono boom dozer blade

Offset backhoe boom dozer blade

94 kg 180 kg

50 kg 3330 kg kg 177 kg 8990 kg 26 kg 4170 kg 11040 kg 2140 kg 1210 kg 550 kg

2770 kg

8490 kg 56 kg 4970 kg 11340 kg

680 kg 55 kg 62 kg 88 kg 61 kg 16 kg 20 kg 77 kg 711 kg 793 kg 943 kg

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71 kg 2780 kg

9150 kg

11350 kg 2770 kg 1900 kg 520 kg


INTRODUCTION

Consumables ( - A.92.A.55) CX135SR

FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application. ATTENTION: You must respect the operating conditions for the different ingredients.

Hydraulic uid CASE AKCELA hydraulic uid is specially designed for high pressure applications and for the CASE hydraulic system. The type of uid to be used depends on the ambient temperature. •

TEMPERATE COUNTRIES - 20 °C to + 40 °C CASE AKCELA HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)

HOT COUNTRIES 0 °C to + 60 °C CASE AKCELA HYDRAULIC EXCAVATOR FLUID "HOT CLIMATE" (MS 1230. ISO VG 100. DIN 51524 PART 2 HV)

COLD COUNTRIES - 40 °C to + 20 °C CASE AKCELA HYDRAULIC EXCAVATOR FLUID "COLD CLIMATE" (MS 1230. ISO VG 22. DIN 51524 PART 2 HV)

BIODEGRADABLE FLUID - 30 - +40 °C This yellow uid can be mixed with standard uid. If this liquid is used, it is advisable to completely drain the hydraulic circuit . CASE AKCELA HYDRAULIC EXCAVATORS FLUID BIO (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)

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

Grease "Extreme Pressure" multi-purpose grease •

CASE AKCELA MOLY GREASE 241H EP-M (251H EP-M NLGI2) with lithium and molybdenum bisulphide soap.

CASE AKCELA 251H EP MULTI-PURPOSE GREASE (251H EP. NLGI 2) with lithium and calcium soap.

CASE AKCELA PREMIUM GREASE EP-2 (NLGI 2) with lithium soap.

HYDRAULIC HAMMERS Use only CASE AKCELA PREMIUM GREASE EP-2 (NLGI 2) grease with lithium soap.

Engine oil CASE AKCELA NO. 1 ENGINE OIL is recommended for the engine. This oil provides correct lubrication for your engine in all working conditions. If CASE AKCELA NO. 1 ENGINE OIL Multigrade cannot be obtained, use oil corresponding to one of the following categories: ACEA E5. MS 1121. API CH-4.

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INTRODUCTION

CRIL03H015F01

1

OIL USE RANGE 1.

Mineral-based

2.

Semi-synthetic based

3.

Synthetic based

Fuel Use fuel that is compliant with ASTM (American Society for Testing and Materials) standard D975. •

Use Grade No 2 fuel. The use of other types of fuel can result in a loss of power and may cause high fuel consumption.

When the temperature is very cold, the use of a mixture of No 1 and No 2 fuel is permitted. See your fuel vendor for winter fuel requirements in your area.

If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting.

IMPORTANT: In cold weather, ll the fuel tank at the end of the day’s work to prevent condensation from forming. FUEL STORAGE Long storage can lead to the accumulation of impurities and condensation in the fuel tank. Engine trouble can often be traced to the presence of water in the fuel. The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing. CASE AKCELA PREMIUM ANTI-FREEZE LRD -25°C For environments with temperatures falling to - 25 °C, do not mix with water. CASE AKCELA PREMIUM ANTI-FREEZE (MS 1710) For environments with temperatures falling to - 38 °C, use with water in a proportion of 50/50. IMPORTANT: Do not mix products of a different origin or a different make. The system must be topped up with the same product.

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INTRODUCTION

Environment Before carrying out any servicing operation on this machine and before disposing of used uids or lubricants, always think of the environment. Never throw uid or oil on the ground and never keep them in leaking receptacles. Contact your local ecological recycling centre for information on appropriate ways to dispose of these substances.

Components made from plastic or resin When cleaning plastic parts, (the console, the instrument panel, the indicators etc...) avoid using petrol, parafn, paint solvents etc. Use only water, soap and a soft cloth. The use of petrol, parafn, paint solvents, etc, will cause discoloration, cracking or deformation of these components.

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INTRODUCTION

Hydraulic contamination ( - A.92.A.60) CX135SR

CLEANING THE HYDRAULIC SYSTEM General Contamination of the hydraulic system is a major cause of incorrect operation of hydraulic components. Contamination is indicated by the presence of foreign particles in the hydraulic uid. Contamination of the hydraulic system can occur in any of the following situations: 1.

When draining the uid or disconnecting a hydraulic line.

2.

When disassembling a component.

3.

Due to normal component wear.

4.

Due to damaged or worn seals.

5.

Due to a damaged component in the hydraulic system.

All hydraulic systems can function even if they are slightly contaminated. The components of the hydraulic system are designed to support slight contamination. Any increase in the degree of contamination can cause serious problems in the hydraulic system. The following is an incomplete list of these problems: 1.

The cylinder rod seals leak.

2.

Control valve spools do not return to the neutral position.

3.

Control valve spools do not move easily.

4.

Hydraulic uid is too hot.

5.

Hydraulic components wear quickly.

6.

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

7.

Repaired components break down soon.

8.

Cycles are slow; the machine does not have enough power.

If any of the above situations occurs, it is an indication of excessive contamination of the hydraulic system. To eliminate contamination, effectively, refer to PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating (A.10.A - F.30.A.60).

Types of contamination Contamination exists basically in two forms: microscopic or visible. We speak of microscopic contamination when very small particles of foreign bodies are in suspension in the hydraulic uid. These particles are too small to be seen or felt. Microscopic contamination can be detected by identifying the problems relating to microscopic contamination or by laboratory tests. The following are a few examples of problems caused by microscopic contamination: •

The cylinder rod seals leak.

Control valve spools do not return to the neutral position.

The operating temperature of the hydraulic system is too high.

Components wear quickly.

We speak of visible contamination when the presence of foreign bodies can be detected visually, by touch or by smell. Visible contamination can cause the sudden failure of a component. The following are a few examples of problems caused by visible contamination:

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INTRODUCTION •

The uid contains metal or other fragments.

The uid contains air. The uid is dark and thick.

There is a smell of burning in the uid. The uid contains water.

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INTRODUCTION

Product identication ( - A.80.A.10) CX135SR WE

NOTE: For all parts orders, requests for information or assistance, always specify the type and the serial number of the machine to your CASE dealer. Fill out the following lines with the required information: type, year of manufacture, serial number of the machine (manufacturer’s plate), mark, type and serial number of the engine, and serial numbers of hydraulic components.

Manufacturer’s plate

CRIL03H001E01

(1) TYPE

1

(2) YEAR OF MANUFACTURE

(3) SERIAL NUMBER

Engine MAKE

TYPE

SERIAL NUMBER

Serial numbers of hydraulic components COMPONENTS Hydraulic pump Swing reduction gear Travel reduction gear Travel control valve Attachment control valve Swing control valve

SERIAL NUMBER

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INTRODUCTION

Product identication ( - A.80.A.10) CX135SR NA

NOTE: For all parts orders, requests for information or assistance, always specify the type and the serial number of the machine to your CASE dealer. Fill out the following lines with the required information: type, year of manufacture, serial number of the machine (manufacturer’s plate), make, type and serial number of the engine and serial numbers of hydraulic components.

Manufacturer’s plate

CRIL03I175E01

(1)TYPE

1

(2)YEAR OF MANUFACTURE

(3)SERIAL NUMBER

Engine MAKE

TYPE

SERIAL NUMBER

Serial numbers of hydraulic components COMPONENTS Hydraulic pump Swing reduction gear Travel reduction gear Travel control valve Attachment control valve Swing control valve

SERIAL NUMBER

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INTRODUCTION

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REPAIR MANUAL DISTRIBUTION SYSTEMS

CX135SR

27049 1 14/12/2004 A


Contents DISTRIBUTION SYSTEMS - A

PRIMARY HYDRAULIC POWER SYSTEM

A.10.A

CX135SR

SECONDARY HYDRAULIC POWER SYSTEM

A.12.A

CX135SR

HYDRAULIC COMMAND SYSTEM

A.14.A

CX135SR

ELECTRICAL POWER SYSTEM

A.30.A

CX135SR

LIGHTING SYSTEM

A.40.A

CX135SR

27049 1 14/12/2004 A


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

CX135SR

27050 1 14/12/2004 A.10.A / 1


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

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

5

CX135SR

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

7

CX135SR

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

9

CX135SR WE

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

11

CX135SR NA

PRIMARY HYDRAULIC POWER SYSTEM - Seed rates (A.10.A - D.50.A.60)

13

CX135SR

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

13

CX135SR

Hydraulic pump - Service limits (A.10.A.20 - D.20.A.20)

14

CX135SR

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

15

CX135SR

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

16

CX135SR

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

19

CX135SR

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

21

CX135SR

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

24

CX135SR

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

25

CX135SR

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

27

CX135SR

Hydraulic pump - Exploded view (A.10.A.20 - C.10.A.20)

30

CX135SR

Sensing system Sensing system Temperature sensor - Electronic schema (A.10.A.95.90 - C.20.A.50) CX135SR

SERVICE 27050 1 14/12/2004 A.10.A / 2

32


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

33

CX135SR

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

34

CX135SR

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

35

CX135SR

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

36

CX135SR

PRIMARY HYDRAULIC POWER SYSTEM - Pressure test (A.10.A - F.40.A.30)

37

CX135SR

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

39

CX135SR

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

41

CX135SR

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

42

CX135SR

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

44

CX135SR

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

45

CX135SR

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

46

CX135SR

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

47

CX135SR

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

49

CX135SR

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

50

CX135SR

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

51

CX135SR

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

52

CX135SR

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

53

CX135SR

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

54

CX135SR

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

58

CX135SR

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

62

CX135SR

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

63

CX135SR

Hydraulic pump - Pressure test (A.10.A.20 - F.40.A.30)

64

CX135SR

Compensator Compensator - Disassemble (A.10.A.23 - F.10.A.25)

65

CX135SR

Compensator - Assemble (A.10.A.23 - F.10.A.20) CX135SR

Reservoir 27050 1 14/12/2004 A.10.A / 3

67


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

69

CX135SR

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

71

CX135SR

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

72

CX135SR

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

73

CX135SR

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

74

CX135SR

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

75

CX135SR

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

75

CX135SR

Relief valve Relief valve - Troubleshooting (A.10.A.16 - G.40.A.10) CX135SR

27050 1 14/12/2004 A.10.A / 4

76


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10) CX135SR

Capacities Total hydraulic circuit Hydraulic uid reservoir Coolant only

125 L 81 L 7L

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

2 x 117.2 L/min 2 x 54.5 cm³

Hydraulic control pump Fixed ow pump Maximum ow Displacement

21.5 L/min 10 cm³

Secondary hydraulic pump Fixed ow pump Maximum ow Displacement

52 L/min 24.9 cm³

Calibration pressure Pilot circuit main relief valve (± 1 bar) Main relief valve (standard) (± 3 bar) Main relief valve (option) (± 3 bar) Secondary relief valve (boom, dipper and bucket) ( ± 5 bar) Secondary relief valve (swing) (± 4 bar) Secondary relief valve (travel) (± 5 bar) Secondary relief valve (dozer blade) (± 5 bar) Secondary relief valve (backhoe offset) (± 5 bar) Secondary relief valve (boom and dipper) (± 5 bar)

39 bar 343 bar 206 bar 378 bar 280 bar 343 bar 235 bar 235 bar 378 bar

Boom cylinder Barrel diameter Rod diameter Stroke

105 mm 75 mm 1120 mm

Dipper cylinder Barrel diameter Rod diameter Stroke

115 mm 80 mm 1108 mm

Bucket cylinder Barrel diameter Rod diameter Stroke

95 mm 65 mm 881 mm

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

110 mm 70 mm 240 mm

Backhoe-offset cylinder Barrel diameter Rod diameter Stroke

120 mm 65 mm 863 mm

Cylinder leakage - attachment lowering (without load) Boom cylinders (rod retraction) Dipper cylinder (rod extension) Bucket cylinder (rod extension) Full (at the end of the attachment)

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

Control valve Five-section control valve for dipper, boom acceleration, swing, option and right travel. Four-section control valve for dipper acceleration, bucket, boom and left travel. Two-section control valve for dozer blade and backhoe-offset boom. Load holding relief valve for boom and dipper. Swing motor Fixed ow motor with axial pistons. Automatic disk brakes. 13.4 RPM 64 cm³ 100 L/min 19.2 284.7 Nm 23 bar xx L/min

Chassis upperstructure swing speed Displacement Working ow Reduction ratio Braking torque Minimum brake release pressure Acceptable motor leakage Travel motor Two-speed motor with axial pistons. Automatic disk brake. Slow speed High speed Gradeability Tractive effort Displacement Working ow Reduction ratio Braking torque (excluding reduction gear) Acceptable motor leakage

3.2 km/h 5 km/h 70 % (35°) 11 000 daN 52.7/34 cm³ 117.2 L/min 72 145 Nm xx L/min

Attachment Breakout Breakout Breakout Breakout

8970 5950 6390 5960

force force (dipper 2.11 m - backhoe-offset) force (dipper 2.39 m) force (dipper 2.85 m)

27050 1 14/12/2004 A.10.A / 6

daN daN daN daN


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10) CX135SR

CRIL03K035H01

1

Location of secondary relief valves

27050 1 14/12/2004 A.10.A / 7


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Calibration pressure Item

(A) (B) (B1) (B2) (C) (D) (D1) (E) (F) (G) (H) (I) (J) (K) (L) (O) (P) (S) (T) (U) (W1)

(W2)

Description

Nominal Pressure For pressure setting Secondary pressure with one procedures, relief refer to: pressure read on the turn of the machine screw setting (or for a shim*) Main pump negative pressure 27 bar Hydraulic pump - Pressure test (A.10.A.20 - F.40.A.30) Pilot accumulator check Accumulator - Check (A.14.A.30 - F.40.A.11) 343 bar to 346 bar 178 bar Main relief valve(standard Relief valve - Pressure setting 60 L/min pressure) (A.10.A.16 - F.45.A.70) Boom raising port secondary 378 bar to 391 bar 212 bar Relief valve - Pressure test relief 20 L/min (H.20.B.16 - F.40.A.30) 378 bar to 391 bar Boom cylinder safety valves Safety valve - Pressure 20 L/min secondary relief setting (H.20.B.15 - F.45.A.70) Boom lowering port secondary 378 bar to 385 bar 212 bar Relief valve - Pressure test relief 20 L/min (H.20.B.16 - F.40.A.30) 212 bar Dipper out port secondary relief 378 bar to 395 bar Relief valve - Pressure test 20 L/min (H.25.B.16 - F.40.A.30) 378 bar to 395 bar Dipper cylinder safety valves Safety valve - Pressure 20 L/min secondary relief setting (H.25.B.15 - F.45.A.70) 378 bar to 393 bar 212 bar Dipper in port secondary relief Relief valve - Pressure test 20 L/min (H.25.B.16 - F.40.A.30) Bucket open port secondary 378 bar to 395 bar 212 bar Relief valve - Pressure test relief 20 L/min (H.30.C.16 - F.40.A.30) Bucket close port secondary 378 bar to 397 bar 212 bar Relief valve - Pressure test relief 20 L/min (H.30.C.16 - F.40.A.30) 42 bar 39 bar 20 bar Pilot circuit main relief Relief valve - Pressure test (A.14.A.16 - F.40.A.30) 117 bar RH swing port secondary relief 280 bar to 285 bar Relief valve - Pressure test 78 L/min (F.40.C.16 - F.40.A.30) 280 bar to 285 bar 117 bar LH swing port secondary relief Relief valve - Pressure test 78 L/min (F.40.C.16 - F.40.A.30) 348 bar Forward travel secondary relief 348 bar 10 bar* Relief valve - Pressure test (F.10.F.16 - F.40.A.30) 348 bar Reverse travel secondary relief 348 bar 10 bar* Relief valve - Pressure test (F.10.F.16 - F.40.A.30) 275 bar to 230 bar 212 bar Backhoe-offset to the right Relief valve - Pressure test 20 L/min secondary relief (H.20.D.16 - F.40.A.30) 216 bar to 188 bar 212 bar Backhoe-offset to the left Relief valve - Pressure test 20 L/min secondary relief (H.20.D.16 - F.40.A.30) 212 bar Dozer blade and backhoe-offset 206 bar to 215 bar Relief valve - Pressure test 54 L/min main relief (A.12.A.16 - F.40.A.30) Dozer blade lowering secondary 235 bar to 250 bar 212 bar Relief valve - Pressure test relief 20 L/min (J.40.F.16 - F.40.A.30) Dozer blade raising secondary 235 bar to 250 bar 212 bar Relief valve - Pressure test relief 20 L/min (J.40.F.16 - F.40.A.30) As recom212 bar Option circuit secondary relief mended by manufacturer As recom212 bar Option circuit secondary relief mended by manufacturer

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A D.20.A.40) CX135SR WE

Digital tester assembly

CRIL03G253E00

1

DESCRIPTION Tester assembly for Multi-Handy 2051 Multi-Handy 2051 tester Pressure sensor (0 bar to 600 bar) Straight union for sensor Elbow union for sensor Engine speed sensor Cable (length 5 m) Electric plug 220 volts 50 Hz Cigarette lighter cable Instruction Sheet Carrying case

QUANTITY 1 2 2 1 1 3 1 1 1 1

CODE E54444449 D5444448 V5344460 W5344461 X5344462 Z5344463 E3144472 D5344467 E5344468 N5344476

QUANTITY 1 2 2

CODE RE3 Z5344486 D4323359 B8230183

The Multi-Handy tester is used to: Check pressure (two pressure scales) Check differential pressure (delta P) Check temperature Check engine rpm Check the ow 600 litre turbine

CRIL03G254E00

2

DESCRIPTION Turbine Plates M45x2 Flange diameter 24 mm

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM 4 8

Semi-ange Screw M12 length 75 mm

D4024267 Z1232983

Union assembly for testing pressure and ow

CRIL03G258E00

3

DESCRIPTION Union assembly for testing pressure and ow

CODE CAS30038

Set of high pressure hoses

CRIL03G259E00

4

DESCRIPTION Set of high pressure hoses

CODE CAS30036

27050 1 14/12/2004 A.10.A / 10


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A D.20.A.40) CX135SR NA

Digital tester assembly for pressure measurement

CRIL03G255E00

1

DESCRIPTION Digital tester assembly for pressure measurement

CODE OEM1652

Digital tester assembly for pressure and temperature measurement

CRIL03G256E00

2

DESCRIPTION Digital tester assembly for pressure and temperature measurement

CODE OEM1653

Flowmeter

CRIL03G257E00

3

DESCRIPTION Flowmeter for a ow of < 75 GPM Flowmeter for a ow of > 75 GPM

CODE CAS10280 OEM1240

27050 1 14/12/2004 A.10.A / 11


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Union assembly for testing pressure and ow

CRIL03G258E00

4

DESCRIPTION Union assembly for testing pressure and ow

CODE CAS40023A + CAS40035

Set of high pressure hoses

CRIL03G259E00

5

DESCRIPTION Set of high pressure hoses

CODE CAS30036

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Seed rates (A.10.A D.50.A.60) CX135SR

CRIL03K87F01

1

Main pump ow curve and pressure •

Pump body ow and accumulated pressures for a new pump •

Pressure (P) is equal to two accumulated pressures in the two pump bodies.

Curve (Pi) gives the main pump ow (1 body) compared with the negative pressure (Pi).

Curve (q) gives the minimum ow for a pump body (accumulated pressures) (Pi).

Hydraulic pump - Special tools (A.10.A.20 - D.20.A.40) CX135SR

CRIL03G165E01a

1

Pump bracket (shaft side) Used to secure the pump in the upright position during pump removal and assembly. To be made locally. (A) Diameter 150 mm (B) Diameter 50 - 80 mm 27050 1 14/12/2004 A.10.A / 13


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM (C) 65 mm

Hydraulic pump - Service limits (A.10.A.20 - D.20.A.20) CX135SR

Description of parts Clearance between the piston and the cylinder bore Play between the piston, shoe and guide Shoe thickness Free height of cylinder block springs Height of the thrust plate and the spherical bushing

Wear limit

Action

Standard dimension 0.039 mm

0.067 mm

Replace the cylinder assembly

0.1 mm

0.3 mm

4.9 mm 41.1 mm 12 mm

4.7 mm 40.3 mm 11 mm

Replace the piston or the piston wear plate assembly Replace the pistons Replace the springs Replace the thrust plate and the spherical bushing

Overhaul dimension of the cylinder block, the valve plate and the swash plate 0.1 Ra or less Standard roughness after grinding 0.8 Ra Roughness of the surface at the wear limit

Valve plate (sliding contact surface) Swash plate (at the thrust plate) Cylinder block (sliding contact surface) Irregularity of each surface

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Static description (A.10.A - C.30.A.20) CX135SR

The hydraulic diagram is available as a poster at the end of this manual. For easier understanding, the same legend is used for components appearing in the hydraulic sections and on the poster.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Dynamic description (A.10.A - C.30.A.10) CX135SR

TRAVEL Functions HIGH SPEED

LOW SPEED STRAIGHT-LINE TRAVEL

Description High speed is obtained by changing the travel motors from large displacement to small displacement. When the pressure increases too much, the motors automatically change to low speed. Low speed is obtained when the travel motors are changed to high displacement. If you want to use the attachment or the swing during travel, the machine will continue in a straight line without zig-zagging.

Refer to TRAVELLING Travel - Hydraulic schema (F.10.F - C.20.A.20)

Description When the swing control is in the neutral position, the motor and reduction gear assembly is braked. When the swing is operated, the motor and reduction gear assembly brake is released. When the swing control is in the neutral position and the boom, dipper or bucket is used, the swing moto-reduction gear assembly brake is released. The swing is braked 5 seconds after putting the control into neutral or when the attachment is no longer operated. The swing torque is maintained by the priority valve incorporated in the control valve. When working in a trench, the swing variable priority valve is activated to provide sufcient ow to the dipper. This function reduces the number of rebounds when the swing is stopped. A protective valve is mounted on the swing motor.

Refer to SWINGING Circular swing Hydraulic schema (F.40.C C.20.A.20)

TRAVELLING Travel - Hydraulic schema (F.10.F - C.20.A.20) TRAVELLING Travel - Hydraulic schema (F.10.F - C.20.A.20)

SWING Functions BRAKING

PRIORITY

ANTI-REBOUND

SWINGING Circular swing Hydraulic schema (F.40.C C.20.A.20) SWINGING Circular swing Hydraulic schema (F.40.C C.20.A.20)

ATTACHMENT Functions BOOM LIFTING

Description An internal spool is used to provide two ows when raising the boom. BOOM LOWERING, Boom lowering is made possible by unlocking the load holding system which is incorporated in the control valve. LOAD HOLDING BOOM LOWERING, The acceleration and the ow reduction pressure ADDITIONAL information are controlled via the additional supply in SUPPLY the boom spool and the continuous connection between the supply and the return. BOOM LOWERING, The pressure points are controlled by the circuit which keeps part of the supply ow for the free passage. This VIBRATION is used to reduce vibration. PREVENTION DIPPER OUT An internal spool provides two ows for the dipper. DIPPER IN, LOAD HOLDING DIPPER IN, ADDITIONAL SUPPLY

Refer to BOOM Lift - Hydraulic schema (H.20.B - C.20.A.20) BOOM Lift - Hydraulic schema (H.20.B - C.20.A.20) BOOM Lift - Hydraulic schema (H.20.B - C.20.A.20)

BOOM Lift - Hydraulic schema (H.20.B - C.20.A.20)

DIPPER Lift - Hydraulic schema (H.25.B - C.20.A.20) Dipper in is made possible by unlocking the load holding DIPPER Lift - Hydraulic schema system that is incorporated in the control valve. (H.25.B - C.20.A.20) The additional supply cancellation valve makes DIPPER Lift - Hydraulic schema combined movements quicker. (H.25.B - C.20.A.20)

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Functions CUSHION VALVE

BOOM OFFSET BUCKET OPENING AND CLOSING OPTION 1 OPTION 2

Description Refer to Shocks experienced when the attachment stops moving are reduced by the cushion valve which incorporates pilot heating. A separate circuit (pump and control valve) supplies the BOOM Swing - Hydraulic offset. schema (H.20.D - C.20.A.20) ARM TOOL ATTACHMENT Tilt - Hydraulic schema (H.30.C C.20.A.20) An option section incorporated in the control valve can DIGGING Hammer - Hydraulic be used as a breaker or a grab, for example. schema (J.20.E - C.20.A.20) A supplementary two-section control valve is added to DIGGING Hammer - Hydraulic the main control valve to control a backhoe-offset boom schema (J.20.E - C.20.A.20) and/or a dozer blade.

OTHERS Functions DOZER BLADE

PUMP FLOW REDUCTION INFO

Description Refer to A separate circuit (pump and control valve) supplies the LANDSCAPING Dozer blade blade. - Hydraulic schema (J.40.F C.20.A.20) Is used to reduce power consumption by decreasing the See following page pump ï&#x20AC;&#x201A;ow when the machine is not under load or the controls are in neutral.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

CRIL03J157G01

1

Controls in neutral position (1) (3) (5) (B27)

Low pressure pump Pressure limiter Calibrated port Travel pilot pressure switch

(2) (4) (B26)

Pressure limiter Calibrated port Upper pilot pressure switch

In neutral with the engine running, some of the ow from the low pressure pump (1) fed to (PP) is divided by a calibrated restrictor bridge. One part passes through the two travel spools, and the other passes through all the other spools before rejoining the general return circuit. When the spools are moved, these circuits will be locked, which will close upper pilot (B26) and travel pilot (B27) pressure switches.

Pump outlet (A1) enters (P2) on the control valve, while pump (A2) enters in (P1), passing through the control valve via the free passages. They are controlled by two pressure limiters (2) and (3) set to 26,7 bar under 27 L/min and two restrictors (4) and (5). Both these pressures are sent to the HP pumps via ports (Pi1) and (Pi2) to set them at minimum ow.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Stack valve - External view (A.10.A.18 - C.10.A.40) CX135SR

CRIL03L043H01

1

Control valve block with options Description of control valve block (62) (64)

Main relief valve Safety valve (option)

(63) (65) 27050 1 14/12/2004 A.10.A / 19

Safety valve Screw


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM (66) (68) (71) (73) (79) (A-A)

Screw Screw Rod Rod Dozer blade and backhoe-offset relief valve Refer to Stack valve - Sectional view (A.10.A.18 C.10.A.30)

(67) (69) (72) (74) (90) (B-B)

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Screw Plug assembly Nut Nut Plug assembly Refer to Stack valve - Sectional view (A.10.A.18 - C.10.A.30)


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Stack valve - Sectional view (A.10.A.18 - C.10.A.30) CX135SR

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

CRIL03J093F01

1

Section A-A (1) (3) (5) (11) (13)

Timing gear case Spool assembly - option Boom spool assembly 2 Large cap Small cap

(2) (4) (6) (12) (32)

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Spool assembly - RH travel Spool assembly - swing Dipper spool assembly 1 Seal Plug assembly


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

CRIL03J092G01

2

Section B-B (7) (9) (11) (13) (15) (42) (47) (61) (78) (84)

Dipper spool assembly 2 Bucket spool assembly Large cap Small cap Large cap Seal Cap Outlet plate Inlet plate - option Dozer blade spool assembly

(8) (10) (12) (14) (40) (44) (48) (62) (83)

27050 1 14/12/2004 A.10.A / 22

Boom spool assembly 1 Straight-line travel spool assembly Seal Small cap Spool assembly - LH travel Spring Spool Main relief valve Backhoe-offset spool assembly


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

CRIL03L045F01

3

Other sections Section Input section (C-C)

Description

(D-D)

RH travel and straight-line spool section

(E-E)

Option and LH travel section

(F-F)

Swing and bucket section

(G-G)

Boom 1 and 2 section

(H-H)

Dipper 1 and 2 section

(I-I)

Output section with swing priority spool, negative pressure valves and dipper recycling valve. Output section with ï&#x20AC;&#x201A;ow re-injection spool.

(J-J)

Refer to Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30) Control valve - Sectional view (F.10.F.14 C.10.A.30) Control valve - Sectional view (F.10.F.14 C.10.A.30) Control valve - Sectional view (F.40.C.14 C.10.A.30) Control valve - Sectional view (H.30.C.13 C.10.A.30) Control valve - Sectional view (H.20.B.14 C.10.A.30) Control valve - Sectional view (H.25.B.14 C.10.A.30) Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30) Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30)

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30) CX135SR

CRIL03J089F01

(16) (17) (18) (19) (62) (69)

1

Valve Spring Seal Seal Main relief valve Plug

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30) CX135SR

CRIL03J088F01

1

Section I-I - Swing priority spool, negative pressure valves and dipper recycling valve. (21) (42) (44) (46) (50) (52) (54)

Plug Seal Spring Cap Seal Spool assembly Seal

(41) (43) (45) (49) (51) (53) (55)

Spool Spring seat Spool end Plug Spring Back Up Ring Negative pressure main relief valve

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

CRIL03J104F01

2

Section J-J - Flow re-injection spool (42) (44) (47) (56)

Seal Spring Cap Plug

(43) (45) (48)

Spring seat Spool end Spool

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic pump - Sectional view (A.10.A.20 - C.10.A.30) CX135SR

CRIL03J050H01

(1) (3) (5) (7)

Shaft Cover Spherical bushing Screw

(2) (4) (6) (8)

1

Seal Seal Centring stud Nut

27050 1 14/12/2004 A.10.A / 27


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM (9) (11) (13) (15) (17) (19) (21) (23) (25) (27) (29) (31) (33) (35) (37) (39) (41) (43) (45) (47)

Seal Ring Seal Swash plate Seal Seal Screw Cylinder plate Screw Shaft Centring stud Main pinion Plug Intermediate housing Plug Spring Thrust plate Seal Front ange Bearing Rear ange

(10) (12) (14) (16) (18) (20) (22) (24) (26) (28) (30) (32) (34) (36) (38) (40) (42) (44) (46)

Back-up ring Control piston Control pivot Seal Seal Ring Lifting ring Piston Rear housing Rear cylinder block Seal Needle roller bearing Seal Front cylinder block Seal Front housing Piston wear plate Plug Snap ring Bushing

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

CRIL03K028G01

2

Secondary hydraulic pump coupling (1) (3) (5) (7) (9) (11) (13) (15) (17)

Pinion Snap ring Cover Snap ring Pin Bearing Centring stud Seal Power take-off housing

(2) (4) (6) (8) (10) (12) (14) (16)

Bearing Seal Screw Snap ring Spacer Intermediate pinion Plug Screw

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic pump - Exploded view (A.10.A.20 - C.10.A.20) CX135SR

CRIL03J178H01

(1) (4) (7)

Screw Snap ring Bushing

(2) (5) (8)

1

Hydraulic control pump Bushing Shaft

27050 1 14/12/2004 A.10.A / 30

(3) (6) (9)

Seal Bearing Nut


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM (10) (13) (16) (19) (22) (25) (28) (31) (34) (37) (40) (43) (46) (49) (52) (55) (58) (61) (64) (67)

Screw Back-up ring Regulator block Seal Rear ï&#x20AC;&#x201A;ange Rear housing Swash plate Piston Spring Needle roller bearing Intermediate housing Lifting ring Cylinder plate Seal Screw Seal Secondary hydraulic pump Seal Centring stud Screw

(11) (14) (17) (20) (23) (26) (29) (32) (35) (38) (41) (44) (47) (50) (53) (56) (59) (62) (65)

Centring stud Seal Seal Ring Control piston Screw Seal Bushing Thrust plate Rear cylinder block Main pinion Screw Screw Seal Seal Centring stud Plug Seal Cover Locking dowel

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(12) (15) (18) (21) (24) (27) (30) (33) (36) (39) (42) (45) (48) (51) (54) (57) (60) (63) (66)

Seal Ring Control pivot Back-up ring Screw Seal Plug Piston wear plate Spherical bushing Cylinder plate Seal Nut Needle roller bearing Seal Cover Centring stud Screw Power take-off Seal Front housing


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Sensing system Temperature sensor - Electronic schema (A.10.A.95.90 - C.20.A.50) CX135SR

CRIL03K145F01

1

Circuit layout (1)

Coolant temperature indicator

Audible alarm device (3) (B1) Coolant solution temperature sensor (B10) Hydraulic oil temperature thermo-switch

(2) (A2) (B9) (P1)

CRIL03G094E03

2

Timing diagram

27050 1 14/12/2004 A.10.A / 32

Coolant or hydraulic oil overheating indicator lamp Engine electronic control box Coolant solution temperature sensor Instrument panel


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A F.35.A.40) CX135SR

1.

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

2.

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

3.

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

4.

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

5.

Operate the boom, swing and travel controls in both directions to warm up all the circuits to 44 - 55 °C.

27050 1 14/12/2004 A.10.A / 33


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Case cx135sr crawler excavator service repair manual  
Case cx135sr crawler excavator service repair manual  
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